Richard,

I believe that you could get significant cost savings by designing your own MCU board, but you have to look at the commmonalitly of all of your deifferent applications and design a board which will satisfy all of them. For the applications that don't need some of the features, you would just leave them off for that application. You also need to think about the cost of getting CE, FCC, UL, CSA, VME, etc. approvals. Also the cost of the manpower to achieve these approvals. Also how fast would you like to implement this changeover? If manpower is limited, it could take at least a couple of years to get the board designed, get the various agency approvals and get the product onto the market. I'm not trying to discourage you , just giving you a picture of the magnitude of the project.

Jacob