Creating reliable code for embedded systems is the art of balancing low-level hardware access with high demands for stability, real-time performance, power efficiency, and security. Even experienced developers can make mistakes that lead to hard-to-detect failures and serious security vulnerabilities. Here is a summary of the most common — yet most critical — mistakes in professional embedded development, along with best practice suggestions on how to avoid them.
Incorrect use of dynamic allocation (e.g., malloc
, calloc
) without proper supervision can result in memory fragmentation and leaks, or overflow, which in turn lead to performance degradation or even system restarts. Failing to free resources (free
) or allocating them multiple times without controlling the data lifecycle are common issues that cause system instability. Additionally, improper memory access (e.g., out-of-bounds pointers, use of uninitialized memory) can result in hard-to-detect runtime errors and potential security vulnerabilities.
Our suggestion:
It is recommended to use static allocation or dedicated real-time memory managers (RTOS-aware memory pools).
Using blocking functions, such as delay()
or I/O operations within interrupt service routines, is a serious mistake that can lead to system hangs or the loss of other critical events. Performing heavy operations inside an ISR can increase the blocking time for other interrupts and violate real-time (RT) requirements. ISRs should be kept as short and deterministic as possible — their main role is to quickly capture and store information.
Our suggestion:
Minimizing ISR logic and delegating application-level processing to the main program loop or an RTOS task.
Improper management of access to shared resources—such as global variables, buffers, or hardware interfaces—can lead to race conditions, data loss, and hard-to-reproduce execution errors. In real-time systems, where multiple threads or interrupts operate concurrently, the absence of synchronization may result in extremely difficult issues to detect and debug. Neglecting safeguards in this area is one of the most common and costly mistakes in embedded code.
Our suggestion:
Using protection mechanisms for critical sections, such as semaphores, mutexes, or disabling interrupts during resource access.
Using polling — the technique of cyclically checking the status of peripheral devices or registers — leads to unnecessary CPU cycle consumption and increased energy usage, particularly in low-power systems. “Polling is easy to implement and easier to misuse. In real-time systems, it’s often the root of lost responsiveness” — as Jean Labrosse stated, founder of Micrium RTOS. This approach does not scale well in multitasking or real-time environments, as it blocks other processes and increases timing jitter.
Our suggestion:
Conducting interrupts or low-level power-saving mechanisms (such as sleep, WFI – Wait For Interrupt, or WFE – Wait For Event) to improve energy efficiency and system responsiveness.
The watchdog is a critical component for monitoring the correct operation of embedded software — when a system hang is detected (e.g., due to an infinite loop), it automatically triggers a system reset, restoring device functionality. However, failing to properly “feed” the watchdog can also cause unnecessary resets if not correctly synchronized with the application’s execution cycle.
Our suggestion:
Regularly feeding the watchdog only after successfully passing through all critical sections of the application.
Improperly set prescalers, clocks, or SPI/UART/I2C operation modes can lead to subtle data transmission errors. This is particularly risky when configuring input peripherals such as ADCs or digital inputs, where incorrect timing can corrupt received data. Often, the default configuration generated by the HAL does not meet the project’s actual needs.
Our suggestion:
Manual register configuration or thorough analysis of the code generated by tools like CubeMX
or ConfigTool
is recommended.
Unit tests run only in a simulator will not detect, for example, pin interference, propagation delay issues, or physical errors in the PCB. They also do not allow verification of proper cooperation with peripherals such as sensors, converters, or communication interfaces.
Our suggestion:
It’s recommended to conduct automated integration tests, hardware-in-the-loop (HIL) testing and debugging on the target board.
You can learn more about HAL testing here:
What is Hardware-in-the-Loop (HIL) Testing And Simulation? A Complete Guide for Engineers
Many developers forget to check error codes and fail to implement timeouts in operations that depend on hardware or bus responses. According to VDC Research, 35% of embedded project delays are linked to undetected communication failures or lack of robust error-handling routines. Lack of separation between error detection and handling mechanisms prevents effective management of the system’s transitional states. Incorrect timeout configuration in protocols such as I²C, SPI, or UART can lead to bus lockups or improper synchronization between devices.
Our suggestion:
Applying software watchdogs, hardware timeouts, and error logging.
In a project focused on modernizing an advanced optical device, the InTechHouse team faced the challenge of upgrading outdated electronics and embedded software without altering the mechanical or optical components of the system. The main issues involved limited hardware resources, a lack of original code documentation, and the need to ensure precise real-time performance.
InTechHouse engineers developed new firmware using modern STM32 components and optimized the control logic, eliminating previous issues related to poor error handling and excessive CPU usage. The project was a complete success — the modernized system achieved improved stability, enhanced functionality, and greater energy efficiency, allowing the client to confidently continue production and expand to new markets.
You can read more about this specific case here:
https://intechhouse.com/case-study/modernizing-embedded-electronics-and-software-for-advanced-optical-equipment/
Creating robust software for embedded systems is about more than just technical skills — it also requires discipline, attention to detail, and a deep understanding of both the hardware and software layers. Consciously avoiding the mistakes outlined in this article and applying structured development practices, such as proper resource management, thorough testing, and clear error handling, can ensure easier long-term maintenance of the codebase.
If you’re looking for an experienced partner in embedded software development, we invite you to collaborate with InTechHouse. Our team combines deep engineering expertise with hands-on experience in commercial and industrial projects, offering end-to-end support — from concept and design to implementation and testing. Trust experts who understand your needs and book a free consultation.
Can excessive optimization be harmful?
Yes — premature or aggressive optimization can make debugging more difficult, reduce code readability, and introduce hard-to-detect bugs, especially in low-level code.
Why is it worth separating error detection from error handling?
Separating these mechanisms improves code readability, allows for more flexible responses (e.g. retries, logging, safe shutdown), and makes testing and maintenance easier.
What are the consequences of missing regression tests in an embedded project?
Without regression tests, new code changes can break previously working functionality, which is often difficult to detect in embedded systems and may lead to failures in production.
Why is initializing all variables so important?
Uninitialized variables may contain random data from memory, leading to unpredictable program behavior and hard-to-detect bugs. This is especially true for types like int
, where uninitialized values can fall anywhere within a large range — and cause logical or safety-critical faults.
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All rights reserved