Custom vs. COTS Image Sensors: A Strategic Decision

Choosing between custom-designed and commercial off-the-shelf (COTS) image sensors is a critical decision that impacts product differentiation, market reach and long-term costs. While COTS sensors offer convenience, custom solutions provide tailored performance and competitive advantages. At ISDI, we offer both standard CMOS image sensors and specialized custom design services to meet diverse customer needs.

Why Choose Custom? Requirements, Markets and Cost

Companies typically opt for a custom image sensor when existing commercial options fall short of their product's specific requirements. COTS sensors are typically developed for broad market appeal and general-purpose applications. However, industries like defence, aerospace, semiconductor inspection and advanced medical devices, frequently demand higher performance that standard offerings simply cannot deliver, making custom design the only viable path.

From a market perspective, custom sensors enable companies to succeed in niche markets or differentiate their products in mass markets. By integrating a unique sensor, businesses can create a product that stands out, securing a competitive edge rather than competing solely on price with products using generic COTS components.

While COTS sensors offer a faster time-to-market and avoid initial non-recurring engineering (NRE) expenses, a custom sensor can offer greater long-term cost efficiency. COTS integration often requires significant system-level modifications (cabling, power, connectors, mechanical interfaces) to accommodate a sensor not originally designed for the application, leading to higher overall costs. In contrast, a custom sensor, despite its higher upfront NRE investment, is purpose-built, reducing the need for costly adaptations later on. Furthermore, clients retain full ownership of the design and control material and production costs, reducing reliance on third-party suppliers and offering unmatched flexibility and value over time.

Real-World Impact: RSP Systems and ISDI

Our collaboration with RSP Systems highlights the tangible benefits of custom design. Martin Schjoldager Nielsen, Technology & Innovation Director at RSP SYSTEMS, praised ISDI's agile business setup and responsiveness. RSP Systems sought to diversify and stabilize their supply chain, moving from an off-the-shelf CCD to a custom CMOS solution. They needed a sensor that could precisely meet critical parameters like Quantum Efficiency (QE) and dark current for measuring very weak signals with long exposure times, while also enabling a smaller footprint. ISDI's custom design provided a robust, cost-effective solution, showcasing the flexibility and superior control offered by CMOS technology over CCDs.

“The reason for choosing ISDI was the very agile business set up that aligned perfectly with RSP Systems’ needs”

— Martin Schjoldager Nielsen (Technology & Innovation Director, RSP SYSTEMS)

Partnering for Success

Bergkristall Contact Imaqe Sensor — Bergkristall CIS scanner: a custom contact image sensor for high-speed, high-resolution scanning

ISDI developed the Bergkristall custom image sensor for Tichawa Vision GMBH. The BergKristall sensor is an advanced contact image sensor designed for high-speed, high-resolution scanning in industries like printing and semiconductor manufacturing. It offers speeds up to 1 MHz (5 times faster than existing solutions), resolutions up to 4800 dpi, and flexible grayscale options. The innovative dual-resolution pixel design allows it to capture detailed images at different levels, while features like gapless scanning, precise colour pixel alignment, and high-speed data output make it highly effective for demanding applications such as web inspection and wafer analysis. It is a powerful, versatile custom design sensor that delivers fast, detailed, and accurate imaging for very precise industrial tasks.

Nikolaus Tichawa of Tichawa Vision GMBH, emphasized the value of ISDI’s collaborative approach whilst working on the Bergkristall custom image sensor design:

"We got useful and honest information from the beginning. ISDI recommended us to shift some of the functionality into the FPGA because it is more reliable and more effective."

This illustrates how ISDI acts as an extension of your design team, providing expert guidance to achieve optimal and reliable solutions, even for unconventional systems.

Are you considering how a custom image sensor could redefine your product's capabilities? Partner with ISDI to leverage our custom CMOS imaging design expertise and create a unique solution for your market. Contact us at inquiries@isdicmos.com