A Step by Step Guide to Electronic Product Design and Development
A well executed design and development cycle for an electronic product
requires travel through many stages before arriving at a successful
conclusion. Here are the stages that we have determined are needed
to create a well designed electronic product.
Concept
The stage where an idea for a new product, a variation on an existing
product, or the identification of a need for an undefined product causes
research to be done to define a product, a market, and an approach for
manufacturing this product.
Research
The stage at which the product concept is utilized to fuel research that
includes identifying the technology, methods, and vendors involved in
producing the product. This stage of research must result in a detailed
design specification that is used to cost the design process that follows
as well as the estimated manufactured cost of the product. The agency
compliance requirements (U.L., F.C.C., C.E., etc.) are defined now.
Circuit Design
The stage where a schematic diagram is created (usually via computer
drafting software) and a preliminary parts list is created for costing
and prototyping the product.
Packaging and Printed Circuit Design
This is the stage where the device under design gets a suitable enclosure
designed or selected. This enclosure selection as well as connectors,
controls, and diplays must all be resolved before the printed circuit
layout commences. The first step in designing a printed circuits the
mechanical pattern or outline of the board assembly itself.
The major steps in this process are:
A package (housing) is selected or designed. If designed, the mechanical
drawing must be produced of the assembly. If selected, this drawing will be
supplied by the manufacturer.
Nomenclature and graphics for the enclosure will be designed. This may
be applied in the form of labels, overlays, silkscreens, or a combination.
The printed circuit layout commences and resolves the requirements of
the circuit diagram usage of electronic components with the form factor
demanded by the packaging design process.
The printed circuit artwork is processed on film and used by a
manufacturer to etch printed circuit boards for the board assembler.
A silkscreen of part locations to assist in the assembly process is
normally applied on the printed circuit card by the manufacturer.
Prototyping or Trial Production
Sometimes protypes are built before stage 4 (packaging and printed circuit
layout) but the speed and cost advantages of computer aided design are
making this more uncommon. A hand-wired prototype of all or a portion of
the circuit may be required for the design process.
Design Review
The stage where the prototype and initial units are evaluated for function,
appearance, build-cost, and possible enhancements. This process should
result in minor changes but is a must to insure compliance with the
original goals.
Manufacturing Setup including Test Setup
The stage is where the necessary test procedures and apparatus, fixtures
if necessary, and detailed assembly instruction and documents are put in
place in order to yield quality, tested products when quantity production
takes place.
Documentation
The phase where circuit diagrams, parts lists, master printed circuit
artwork, parts sources, software source code and documentation, mechanical
drawings, assembly drawings, and all other items included as part of a
project's deliverables are provided. This package should be sufficient
so as to make the product producible by any qualified source, not just
the parties involved in the design.
Agency Compliance
According to the nature of the product some agency compliance may be
required by law. In addition, some agency compliance may be desirable
for product acceptance or for product liability insurance coverage.
Agency compliance can cost several thousand dollars per agency and can
add months of time to accomplish. It is not to be taken lightly or left
as an afterthought.
Followup
After a product is released into production; the manufacturing facility
experience, the product support data, and the user responses, should all
be reviewed for the purpose of steering future designs and marketing.
Don't forget this crucial step on the road to improved quality, value,
and often lower cost.
Sizing up the Task
If you are contemplating a project, make a copy of this document and put
an estimated time and dollar amount by each stage and sub-stage. Add up
the time and dollars and see if it makes sense. Also, add a name or source
for each of these items. Hopefully Mathews Technical Services, Inc. can aid
or provide you one or more of these stages of development.
Trite But True:
Some seemingly small, but important observations we have made over the years.
There is Good, Cheap, and Fast. You can only have
two of the three at any one time.
If you can buy something, do not build it or anything similar without
some truly overwhelming justification.
Always make a mockup or model, even if it is cardboard with hand drawn
features. It will pay for itself again and again, and you will learn
something crucial each time you build one.
