Can You Build Your Own SCADA System?

Supervisory Control and Data Acquisition (SCADA) systems have become the backbone of industrial automation, enabling real-time monitoring, control, and data analytics across industries such as manufacturing, energy, and water treatment. While there are many off-the-shelf SCADA solutions available today, some businesses and developers still consider building their own SCADA system for greater customization, cost control, and scalability.

But is a DIY SCADA system really feasible? What does it take to build one in today’s industrial landscape? Here’s what you need to know.

Why Build Your Own SCADA System?

There are several reasons why organizations consider a custom SCADA system:

• Flexibility & Customization – Pre-built SCADA software may not fully align with your operational needs. A DIY system allows tailored functionality and interface design.
• Cost Savings – Commercial SCADA licenses and ongoing support can be expensive. A custom-built system can reduce long-term costs, especially if it’s open-source.
• Cybersecurity & Compliance – Some industries require strict control over their data and security. A self-developed SCADA system can be designed with zero-trust architectures and custom security protocols.
• Integration with Modern Technologies – Legacy SCADA systems often struggle to integrate with cloud computing, AI, IoT devices, and blockchain-based security. A DIY approach allows for modern integrations from the start.

Key Components of a Modern SCADA System

1. Data Acquisition & Device Connectivity

A SCADA system needs to communicate with field devices like PLCs, sensors, and RTUs (Remote Terminal Units). The most common industrial communication protocols include:

• OPC UA – A widely used protocol for secure, platform-independent industrial automation.
• MQTT – Ideal for cloud and IoT integrations.
• Modbus, BACnet, and DNP3 – Traditional protocols still in use for legacy equipment.
• RESTful & WebSocket APIs – For seamless integration with web-based applications and third-party services.

2. Data Processing & Historian Storage

Modern SCADA systems don’t just monitor processes—they also store and analyze data for predictive maintenance, trend analysis, and compliance.

• SQL & NoSQL Databases – MySQL, PostgreSQL, and MongoDB can be used for structured and unstructured data storage.
• Time-Series Databases – InfluxDB and TimescaleDB are optimized for industrial time-stamped data.
• Edge & Cloud Data Storage – Edge computing is critical for real-time processing, while cloud storage provides scalability and remote access.

3. User Interface (HMI & Web-Based Dashboards)

A Human-Machine Interface (HMI) allows operators to interact with the SCADA system via control panels, dashboards, and alarms.

• Web-Based HMIs – Built with React, Angular, or Vue.js, offering remote accessibility via browsers.
• Mobile-Friendly Interfaces – Responsive dashboards with notifications and real-time updates for on-the-go monitoring.
• Drag-and-Drop UI Builders – Open-source tools like Node-RED can help simplify UI creation.
• 3D Visualization & Digital Twins – Advanced SCADA systems use Unity or Unreal Engine for 3D plant modeling and simulation.

4. Security & Compliance

Cybersecurity is one of the most critical concerns in SCADA development. The rise in ransomware and cyberattacks on industrial control systems (ICS) makes security-first SCADA design non-negotiable.

• TLS/SSL Encryption – Secure data transmission across networks.
• Zero Trust Architecture – Restricting access and verifying all users/devices.
• Role-Based Access Control (RBAC) – Ensuring that only authorized personnel can access specific functions.
• SIEM (Security Information & Event Management) – Using AI-driven monitoring tools like Splunk or Elastic Security for real-time threat detection.
• Compliance with ISA/IEC 62443 & NIST Standards – Ensuring adherence to industrial cybersecurity best practices.

The Build vs. Buy Dilemma: Should You Really Build Your Own SCADA?

While it’s possible to build a SCADA system from scratch, it requires:

• ✅ Expertise in industrial automation, software development, and cybersecurity
• ✅ Significant development time and resources
• ✅ Ongoing maintenance, compliance, and security updates

If your company has a skilled in-house development team and needs highly customized functionality, a DIY SCADA system may be worth it. However, for most businesses, a hybrid approach—modifying open-source SCADA software—can provide a balance between customization and cost-efficiency.

Final Thoughts

Building a SCADA system from scratch isn’t impossible, but it requires deep technical expertise, a strong security framework, and a commitment to continuous updates. Let’s discuss in the comments! 🚀