A group of soldiers walking on the line during sunrise on a hill.

Defence Forces – It’s Time to Upgrade Your Zebra TC72/77 Devices. Here’s Why

December 9, 2025

defence, defence forces, military, rugged devices

Summary

Zebra Technologies’ TC72/77 mobile computers are officially end of sale from 31 October 25. They will no longer be available to buy and will begin their support-only phase. Defence forces should maintain their security and enjoy increased performance by upgrading to the natural successor of this device, the high-performing TC73/78. Nuffield Technologies is a JOSCAR-accredited hardware and software provider that can help with procurement and bespoke deployment of these devices in many defence force scenarios, including disconnected environments.

Introduction

All good things come to an end. And Zebra’s TC72/77 has indeed been one of those very good things. This rugged workhorse and industry leader has served defence teams across the globe, delivering dependable connectivity, fast processing and proven durability in the toughest rugged environments of all.

Zebra has announced that the TC72/77 models are now end of sale. This means they will no longer be available to buy and will begin their discontinuation journey towards end of service. For defence teams, this means it’s time for an upgrade to a device that will be fully supported and secure.

Zebra recommends the TC73/78 series as the natural successor to the TC72/77. We fully support this recommendation – it’s the best mobile computer in its class on the market, with superior durability, connectivity and form factors. And you get five years of product availability from its release in late 2022, with 10 years of service and support.

In this post, we’ll look at why you must upgrade your devices. We’ll also examine what you’re going to get with the TC73/78 – in terms of features and productivity benefits – compared to the TC72/77.

Finally, we’ll focus on the very particular challenges defence forces encounter, including working in disconnected environments, and reveal how Nuffield Technologies can help. We are a tried-and-tested partner to defence forces and can assist you in designing and managing a bespoke rollout that meets stringent security and compliance demands.

The security and productivity imperative

From 31 October 2025, the TC72/77 will no longer be available to buy and will move into a support phase. The next key milestone is 30 June 2026, when engineering support ends. From this point, Zebra will stop all non-security engineering work, including design revisions, platform updates and integration changes with other components or solutions. The final milestone is 31 December 2030, which marks the end of service support. After this date, Zebra will no longer provide repairs or technical support, and all security updates will have already concluded under Zebra’s LifeGuard policy.

Soldier in warehouse using a Zebra Technologies TC72 mobile computer to scan belts in a warehouse

It’s worth reminding ourselves what ‘unsupported’ really means. Without regular security patches, there is no ongoing work to protect the device from newly discovered vulnerabilities. Any weaknesses in the operating system will remain unaddressed, leaving the fleet – and potentially the wider infrastructure – exposed to risks such as malware, ransomware unauthorised access and other security issues that rely on unpatched systems.

Unsupported devices also create challenges for Cyber Essentials, ISO 27001 and similar frameworks, which require organisations to maintain up-to-date, supported software. Running unsupported Android devices can therefore place compliance at risk and introduce avoidable audit findings.

There’s plenty more to this subject, including issues around out-of-date cryptography and the implications of failing to meet important certifications such as ISO 27001 and Cyber Essentials. Find out more in our blog post 5 Urgent Security Issues for Legacy OS Rugged Devices.

Why upgrading to the TC73/78 is an opportunity

The need to upgrade is clear. However, some defence teams may spend a period of time in proverbial no man’s land, wondering when to push forward with new devices. Something that may spur you on is examining just how much more the TC73/78 can do in comparison with the earlier TC72/77 model.

Looking at the topline benefits, it’s going to:

Do more faster, by running an increased number of demanding applications at once
Show superior adaptability and usability, by converting instantly into a full-featured workstation
Process inventory and assets faster, with advanced range imaging and lightning-fast RFID capture
Connect even more reliably, with the latest wireless technologies such as Wi-Fi 6E and 5G
Prove phenomenally durable, with next-level rugged credentials
Last longer. You get five years of product availability from its release in late 2022, with 10 years of service and support from the first date of sale. It’s supported through Android 16, which will cover the long life of this device

The TC73/78 versus TC72/77 comparison

Here’s a rundown of some of the TC73/78 features, compared to the earlier TC72/77.

90% faster

The new Qualcomm 6490 @ 2.7 GHz octa-core processor is 90% faster than the Qualcomm SD660 processor in the earlier model, with a 400% faster graphics processor. This is what will run those multiple apps at lightning speed.

28% larger display

The TC73/TC78’s six-inch edge-to-edge display is 28% larger than prior generations. It has a higher resolution and brighter display – so screens are crisp and easy to read indoors and outside.

25% more rugged

A new 10 ft./3.05 m drop spec is a 25% increase in drop compared to prior TC7X models, enhancing ruggedness for the harshest environments to minimise product downtime and repair costs.

20% thinner

This newer model is more ergonomic: nearly 20% thinner, lighter and easy for virtually any hand size to hold.

Soldier talking into a Zebra handheld mobile computer working at a desk.

These include extended capacity, BLE and wireless charging.

Other features include:

More memory and storage: up to 8 GB RAM/128 GB Flash with a 2 TB MicroSD slot
The latest wireless networks: faster, future-ready wireless connectivity with 5G, Wi-Fi 6E and Bluetooth 5.2
Incredible barcode read ability. If you choose the advanced range SE55 1D/2D scan engine, you can capture barcodes in hand and as far as 40 ft./12.2 m away
Higher resolution cameras: 16 MP rear and 8 MP front
Superior audio quality: three integrated microphones and two high-quality speakers
Workstation Connect functionality, to turn your device into a full-fledged workstation on demand

Working with a defence specialist rugged provider

Deploying mobile devices for defence forces is rarely an out-of-the-box scenario. For this reason, you’ll want to consult with a specialist provider for defence forces: one that can help you configure hundreds/thousands of devices to exact specifications and ensure they function with existing tactical networks and environments. We can help you with this deployment and with the following services.

Deployment in disconnected environments

Defence forces often work in environments where connectivity is patchy or absent – or where it is restricted for security reasons. We can help ensure you maintain device functionality in these circumstances.

For one defence client, our team created a bespoke security layer for the Android operating system (OS), using Android Enterprise features and the Zebra Mobility DNA suite. This included making functional changes at the OS level to deactivate unnecessary features and enhance security.

Following this successful project, devices could be operated securely to undertake device hardening, file transfer and remote updates. Everything could be delivered offline via existing defence networks, connecting to the host system via USB. Find out more about this defence sector mobile deployment case study.

Four military personnel putting donated foods and clothes on the table.

Android update testing

To align with National Cyber Security Centre (NCSC) best practice and ISO/IEC 27001 certification, you must maintain strong security. This will include incorporating Android security updates in a timely way. However, like many organisations, you may be concerned about the disruption to critical business processes. (The CrowdStrike update outage of 2024 still raises its spectre for many.)

Nuffield Technologies offers an automated Android update testing service that combines automated pre-rollout update testing with manual testing where required. We can automatically test Zebra Android updates and third-party software updates, running literally thousands of automated tests in a fraction of the time it takes manual engineers, and run fully manual tests where appropriate.

Find out more

If you’d like to find out more about the specs of the TC73/78 and how Nuffield Technologies can help defence forces upgrade to these devices, get in touch.

As a Zebra reseller, we can assist you with procurement at preferential rates and in deploying these devices in defence-specific environments.

Further resources:

See a defence mobile deployment case study.