Private Island Networks Scales from Prototype to Panelized Production with DDM Novastar

by John Malboeuf, DDM VP of Sales

Case Study Update Last year, we shared how Private Island Networks, a manufacturer of custom systems to control and trust your network, relies on DDM Novastar equipment to manufacture their specialized hardware. We recently reconnected with Bob Cochran for a progress update on their operations in North Florida and their growing educational initiatives:

“For Betsy, we're still in ramp up / beta mode here in North Florida. My company has been sponsoring projects at local universities, and it has been a lot of fun. We have had some of the students visit and see our SMT line (DDM equipment) in action while we build the Betsy boards they use. We plan to do more of this in the 26/27 academic year and hope to branch out to more universities and sponsor more student groups.”

We here at DDM Novastar are proud to see our customers and equipment playing an active role in training future engineers and supporting hands-on innovation in the classroom and the lab.

Read on below for the full story

Private Island Networks is a Florida-based engineering company that develops advanced networking and video processing systems for defense, infrastructure, and security-conscious markets. Founded and led by veteran electrical engineer Robert Cochran, the company is known for its expertise in Field-Programmable Gate Array (FPGA)-based solutions that give customers deeper control and visibility into network traffic.

As a relatively small company, Private Island blends agility with deep technical expertise, serving as both a product developer and engineering services provider. The company is an official design partner with major FPGA suppliers, including Altera and Lattice Semiconductor.

The Manufacturing Challenge

Private Island’s work demands rapid prototyping and frequent iteration. Traditional contract manufacturing, however, could not keep pace. Outsourcing often required minimum order quantities far higher than the company’s needs, and lead times stretched weeks or months, unacceptable when customers expected hardware within days.

“For defense or secure networking applications, you can’t wait around for contract manufacturers,” Cochran explained. “If you only need five or ten boards by Friday, you’re often out of luck. And you lose control and visibility over the process.”

There were also security considerations. In industries where trust and integrity of hardware are paramount, relying on offshore suppliers carried risks. “You don’t always know what’s going into boards manufactured overseas,” Cochran noted. “Bringing assembly in-house gives us full confidence in our designs.”

Building In-House Capability with DDM Novastar

Private Island invested in two critical pieces of American-made equipment from DDM Novastar:

• LS60V Pick and Place Machine with Vision: a high-precision, mid-volume platform capable of handling complex assemblies.
• SPR-25 Manual Stencil Printer: providing reliable solder paste application for fine-pitch devices.

Together, these machines formed the backbone of Private Island’s in-house SMT line. Cochran quickly discovered advantages beyond speed and independence.

“One of the things I love about the LS60V is how accessible everything is,” he said. “The open lid design might seem unusual at first, but it makes setup, maintenance, and inspection so much easier. It’s a strength.”

Speed, Precision, and Security

With DDM equipment in place, Private Island began turning around prototype and custom boards in record time. In one case, a customer requested a custom design on a Tuesday, and fully assembled boards shipped by Friday.

Private Island’s line routinely handles 0201 discrete components, BGAs down to 0.3mm pitch, and fine-pitch connectors, a testament to both operator skill and the precision of the DDM systems.

Equally important, keeping assembly in-house aligned with Private Island’s core philosophy: trusted supply chains and privacy-first hardware. “For security-focused customers, it matters that our boards are designed and built here in America,” Cochran emphasized.

Support That Makes the Difference

Cochran also credited DDM’s responsive support as a key factor. “They pick up the phone, they walk you through solutions, and they know their machines inside and out. Rich Wendler and the team have been great partners.”

Meet the Betsy™ Board

Having already pushed their DDM equipment to the limits of its precision for assembling their technologically advanced PCBs, in 2025, Private Island announced a new project with ambitions of scale rather than precision. The Betsy board, a maker-style FPGA networking platform designed with education, research, and the privacy-minded community in mind, aims to democratize network security with broad, open-source accessibility and availability.

Currently featured on PrivateIsland.tech , Betsy is designed to make live network traffic visible and programmable at the hardware level. Students and engineers will be able to analyze data packets, apply artificial intelligence for intrusion detection, and even prototype new approaches to cybersecurity and machine learning.

“The idea is freedom through visibility,” said Cochran. “With Betsy, you can see the traffic, manipulate it, and develop your own defenses. It’s a hands-on platform on which the next generation of innovators can learn, experiment, and build the next generation of secure networking tools.”

Betsy’s name underscores that theme. The logo depicts the word inside 13 stars, referencing Betsy Ross’s early American flag. It’s a deliberate contrast to the digital eavesdropping from so many of the consumer electronics available today, and the associated surveillance implications. “So many connected devices invade your privacy,” he offered as an example. “Betsy offers freedom from that.”

Coinciding with the upcoming 250th anniversary of the United States, the Betsy launch carries both technical and patriotic symbolism. “We’re a privacy-minded, American small business,” Cochran explained. “This board is about freedom from being spied upon, and the spirit of American ingenuity.”

From Prototypes to volume production

Betsy also represents a shift in Private Island’s use of DDM equipment. For the first time, the company will push into true volume production, assembling many thousands of units over the next several years.

To do this, Cochran plans to panelize Betsy boards, running six to eight units at once on the LS60V, rather than single assemblies. This transition will require new workflows, tighter yield control, and closer consultation with DDM’s support team.

“There will be challenges, of course,” he said. “But I know DDM will be there as we work through panelization and scale up.”

Conclusion

For Private Island Networks, the journey with DDM Novastar equipment began with solving the challenge of rapid prototyping. Over time, it evolved into a cornerstone of the company’s trusted, in-house manufacturing capability. Now, with the launch of the Betsy board, that investment is enabling a bold step into wider markets.

By combining FPGA expertise, a commitment to privacy, and American-made DDM PCB assembly equipment and support, Private Island is demonstrating how even a small team can deliver big innovation.

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For more information:

Private Island Networks: https://privateisland.tech

“Betsy” is a trademark of Private Island Networks Inc.

Originally published in DENA, Designing Electronics North America
Issue 27, vol. 5, No. 01, January/February 2026
https://flickread.com/edition/html/index.php?pdf=694919671e0ae#1