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Set-top Box

Motorola DVi3600R DVR Set-Top Box Teardown

25 August 2009
The following is an overview of a teardown analysis conducted by IHS Technology Teardown Services.

Overview / Main Features

The Motorola DVi3600R is a private labeled DVR set-top box developed for the Spanish cable service provider Ono. There are little information in terms of publically available product specification but the DVi3600R appears to be a High Definition (HD) QAM/DOCSIS capable set-top with DVR functionalities. The storage capacity of the on board hard disk drive is 320GB. The Motorola STB is a primarily Broadcom-based design (as with previous Motorola STBs) also featuring a ST Micro conditional access IC to support the CAM or TV access card slot on the DVi3600R.

Motorola DVi3600R DVR Set-Top Box Main ImageMotorola DVi3600R DVR Set-Top Box Main Image

Target Market

European Cable Television Service Providers



Motorola DVi3600R DVR Set-Top Box - Main PCB TopMotorola DVi3600R DVR Set-Top Box - Main PCB Top

Pricing and Availability

Pricing - for this kind of product (at the consumer level) is typically meaningless as it is a completely subsidized part of a service package. Cable set-top boxes are typically rented out to subscribers on a monthly schedule in accordance with the service contract which varies region to region and market to market. Since the device cannot function without being properly set-up by a service provider, after-market product and prices have no validity.

Availability - Continental Europe

Volume Estimations

For the purposes of this teardown analysis, we have assumed a lifetime production volume of 1.25M units.

As a reminder, teardown volume production assumptions are primarily used for our cost analysis in terms of amortized NRE and tooling costs, especially for custom components specific to the model being analyzed (mechanical components especially). Unless assumed volumes are different by an order of magnitude, minor changes in volume (say 1 million vs. 2) rarely have a large net effect on our final analysis because of this.

Motorola DVi3600R DVR Set-Top Box - Main PCB BottomMotorola DVi3600R DVR Set-Top Box - Main PCB Bottom

Main Cost Drivers Representing ~72% of total materials cost

Western Digital - WD3200AAJS - Hard Drive - 320GB, 3.5', SATA II, 7200RPM, 8MB Buffer, 3Gb/s

Broadcom - BCM7401JKPB1G - HD Digital Video Solution - SoC, AVC/MPEG2/VC-1, For Satellite, IP, Cable and Watch-And-Record DVR

Broadcom - BCM3254KPBG - Cable Modem - Single Chip Solution, QAMLink, EuroDOCSIS 2.0

Tai Hong Circuit - 6-Layer - FR4

Alps Electric - TTEV6-8S18EA3G - Mixer / AGP Amplifier Module Module Value Line Item (Qty:2)

Hynix - HY5DU121622CTP-D43 - SDRAM - DDR, 512Mb (8M x 16x 4Banks), 2.6V, [email protected] (Qty:4)

Liteon - PE-1500-1M-RoHs - AC Power Adapter - Input: 200-240V~, 50-60Hz, 2A, Output: 12VDC, 3.5A (42W)

ST Microelectronics - STV0362-NIM - DVB-T Receiver - Single Chip, DVB-H Broadcast Compliant (Qty:2)

Broadcom - BCM3420KML - Digital CATV Tuner, CMOS (Qty:2)

Enclosure, Main, Bottom - Stamped / Formed Paint-Loc Steel

Enclosure, Main, Top - Stamped / Formed Paint-Loc Steel, White Painted

Broadcom - BCM3421KML - Digital CATV Tuner, CMOS

Enclosure, Main, Front Panel - White Injection Molded Polycarbonate, Black Printed

Hynix - HY27UF081G2A - Flash - SLC NAND, 1Gb(128Mx8bit), 3.0V

Freescale - SCF60004AF - Multi-Stream Conditional Access IC

Epcos - B39361-X6966-M100 - IF SAW Filter - Bandpass, 36.125MHz (Qty:2)

Nexsem - NX2601CMTR - PWM Controller - Dual, Synchronous, w/ NMOS LDO Controller and 5V Bias Regulator (Qty:2)

Total BOM Cost $162.72

Motorola DVi3600R DVR Set-Top Box Cost AnalysisMotorola DVi3600R DVR Set-Top Box Cost Analysis

What Is Not Included in our Cost Analysis

The total materials and manufacturing costs reported in this analysis reflect ONLY the direct materials cost (from component vendors and assorted EMS providers), AND manufacturing with basic test. Not included in this analysis are costs above and beyond the material manufacture of the core device itself - cost of intellectual property, royalties and licensing fees (those not already included into the per component price), software, software loading and test, shipping, logistics marketing and other channel costs including not only EMS provider and the OEM's margin, but that of other resellers. Our cost analysis is meant to focus on those costs incurred in the manufacture of the core device and exceptionally in some circumstances the packaging and literature as well.

Manufacturing Notes

Country of Origin / Volume Assumptions

Based on markings, the unit was assembled in Taiwan. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were also sourced in Taiwan.

Country of origin assumptions relate directly to the associated cost of manufacturing, where calculated by iSuppli. In the cases of 'finished' sub-assemblies (such as hard disk drive), we do not calculate internal manufacturing costs, but rather assess the market price of the finished product in which case country of origin assumptions may or may not have a direct effect on pricing.

Remember also that labor rates are applied directly only to hand inserted components and systems in our bill of materials, and although regional assumptions do, these new rates do not have a direct effect on our modeled calculations of placement costs for automated SMD assembly lines. "Auto inserted components (such as SMT components) placement costs are calculated by an iSuppli algorithm which allocates a cost per component based on the size and pincount of the device. This calculation is affected by country or region of origin as well.

Motorola DVi3600R DVR Set-Top Box - Enclosure DisassemblyMotorola DVi3600R DVR Set-Top Box - Enclosure Disassembly

Design for Manufacturing / Device Complexity

The DVi3600R has an overall component count of 1778 (excluding box contents), of which, only 109 are mechanical in nature. This complexity metric fits well with other DVR set-top boxes we have seen and only slightly more than the 1708 count of our last Motorola DVR teardown analysis

Component counts have a direct bearing on the overall manufacturing cycle times and costs, and also can increase or decrease overall yields and re-work. Our calculations of manufacturing costs factor counts and more qualitative complexities in the design. The cost of manufacturing is also, to some extent, decreased in this case because of assumed labor rate applied for Taiwan.

Note that manual labor has a much smaller effect on auto-insertion assembly lines (for the Main PCB, for example), where manufacturing costs are much more capital equipment intensive and driven by these investment costs.

Design Notes

Here is a summary of the major components used in the Motorola DVi3600R Set-Top design:

Main PCB

A/V Processing

  • Broadcom - BCM7401JKPB1G - HD Digital Video Solution

I/O & Interface

  • Broadcom - BCM3254KPBG - Cable Modem
  • Freescale - SCF60004AF - Multi-Stream Conditional Access IC


  • Hynix - HY5DU121622CTP-D43 - SDRAM
  • Hynix - HY5DU281622FTP-J - SDRAM

OFront End

  • ST Microelectronics - STV0362-NIM - DVB-T Receiver

Hard Disk Drive

  • Western Digital - WD3200AAJS ( 320GB, 3.5', SATA II, 7200RPM, 8MB Buffer, 3Gb/s)


Motorola DVi3600R DVR Set-Top Box - Box ContentsMotorola DVi3600R DVR Set-Top Box - Box Contents

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