Putting the electronics product design and development process under the microscope
Electronics product design is a complex, multi-stage process that involves a combination of technical, market, and user considerations.
The essential steps of electronics product design and development include:
-
Market and competitor research
-
Requirements elicitation and validation
-
Custom hardware modules and enclosure design
-
Embedded systems engineering
-
Pilot production and validation
-
Manufacturing and certification
-
Product launch and post-launch support
Scroll down to find out more about these steps and the activities they involve.
Step 1: Market and competitor research
Before beginning an electronics product design project, it is critical to understand market needs, identify target customers, and evaluate competitors.
Returning to the home automation startup example mentioned at the beginning of the article, here’s how the research phase would look:
-
Determine who your prospective customers are. Your product could be aimed at tech-savvy homeowners, those interested in reducing energy consumption, or the elderly who require assistance and observation. Other demographic factors to consider include potential customers’ age, income, location, and technological affinity. Depending on your target customer segment, you will be better able to choose an optimal feature set for your device and the appropriate electronics product development technology (think computer vision for elderly care). It is also recommended that you conduct surveys and interviews with prospective customers. This could help you get a better grasp of their needs, concerns, and expectations, providing a definitive direction for further research.
-
Evaluate the size of your target market. In this step, you should assess the overall size of the home automation market ($82.04 billion in 2023), its key segments, such as lighting equipment and security systems, and the market’s growth trends. This information could help you identify the most lucrative opportunities in the smart home industry.
-
Study your competition. Competitor analysis for electronics product design and development entails researching both direct competitors (such as burgeoning home automation companies like SwitchBot and OM Wave) and indirect competitors (such as manufacturers of standalone devices that may not be integrated into larger ecosystems). Specifically, you should study their products’ feature set, customer service options, and marketing mix. You can then summarize the findings of your research using a simple framework such as SWOT analysis and use the insights to fine-tune requirements for your electronics product development initiative and create a distinct value proposition.
It should be noted that the aforementioned tips are more appropriate for companies involved in consumer electronics design and development.
If you work for a life science, biotech, or medical company that produces custom medical or scientific equipment, your market intelligence opportunities may be limited due to NDAs and the novelty of your product.
If that is the case, pay closer attention to patents issued by your competitors, technology trends, compliance regulations, and your research objectives—and reach out to a reputable electronics product development company, such as ITRex for expert assistance with requirements analysis.
Step 2: Requirements elicitation and validation
Electronics product design projects tend to start with a discovery phase—a mix of research and development activities that lay the foundation for creating a new product.
Visit our blog to learn more about the discovery phase of software development and product discovery in projects that are managed in accordance with the Agile methodology principles.
In this article, we will focus solely on the discovery phase in electronics product design and the steps involved:
-
Define the product’s features. To identify a winning feature set for custom electronics, combine insights from Step 1’s customer, competitor, and market research with feedback from internal stakeholders such as your company’s C-Suite and technical specialists. Consider how the product’s functionality can be monetized in ways that are compatible with your company’s business model.
-
Create user personas and usage scenarios. Using the information you have gathered so far, create fictional representations of your target customers, including demographics, needs, pain points, and technology acceptance levels. The latter factor will assist you in envisioning scenarios and contexts in which your product will be used, as well as mapping use cases to product features.
-
Determine the product’s functional and non-functional requirements. Moving on to the next step in our electronics product development guide, it is critical that you understand the device’s functional (i.e., what it is supposed to do) and non-functional (i.e., how the solution works) requirements.
-
Functional requirements. Identify and list all required features based on the discovery insights. For a custom smart home solution, such features may include remote control capabilities, integration with other connected devices, user interface requirements, and automation features. If you are designing a fitness mirror with an AI coach, your functional requirements may include touch and voice interfaces, the ability to create personalized workout plans using AI algorithms, performance tracking, and effective feedback mechanisms. When analyzing functional requirements for electronics product design, you should also consider how the system will respond to specific user interactions or environmental conditions. It is also necessary to map out system interactions and user interface flows, such as error handling and feedback loops.
-
Non-functional requirements. In this step, you should specify the device’s performance criteria, such as response time, reliability, and uptime requirements. Scalability is another important factor to consider, particularly if you intend to enter the consumer IoT market. With a small user base, your smart curtain control system may function well and efficiently use cloud resources. Once your product becomes popular or begins to sell in new markets, your cloud computing costs may skyrocket, and major performance issues will become apparent. Other non-functional requirements that must not be overlooked include data privacy and security functionality, such as data encryption at rest and in transit, and compliance with industry and region-specific standards, from GDPR to HIPAA. Lastly, outline preemptive requirements for software updates, troubleshooting, and ongoing customer support.
-
Following the discovery phase, you should validate the requirements through proof of concept (PoC) and build a prototype to further refine them.
Proof of concept in electronics product design and development
A proof of concept is an early stage of electronics product design that determines the technological feasibility of a proposed idea. PoCs are also common in software development; read this ITRex article to learn more about proof of concept, associated activities, and primary uses for PoC creation.
Suppose your company is engineering a smart door lock with facial recognition capabilities. How could creating a proof of concept benefit your project?
-
During PoC, your IT team or the company you’ve addressed for electronics product design services can select the hardware necessary to support the facial recognition functionality, such as cameras and processing units. You can run initial tests to see if the selected hardware can integrate with the facial recognition software effectively. This includes testing processing speeds, camera resolution, and integration capabilities.
-
You can also experiment with proprietary and open-source facial recognition algorithms, from convolutional neural networks to 3D face recognition, to choose the right technology stack for your project. Specifically, you should check the accuracy of the facial recognition algorithm under various conditions (e.g., different lighting, angles, and facial expressions).
-
As part of your PoC, you can further assemble a simple system that integrates the camera, processor, and facial recognition software to demonstrate the basic functionality—recognizing a face and unlocking the door.
-
A PoC also helps determine how to handle and store data securely and assess what resources are required for the system to function optimally under the current and future workload.
-
Lastly, a PoC in electronics product design and development will give you a better idea of potential legal constraints and considerations in the field of biometric security devices.
The outcomes of the PoC phase should be carefully documented and presented to stakeholders. Based on these insights, they can make a better-informed decision about whether to proceed with full-scale electronics product development or bring the project to a halt.
Electronics product prototyping
Prototyping is a critical stage in the electronics product design and development process that converts theoretical designs into tangible, testable products and results in additional provisions for custom hardware and software development based on user feedback.
Key activities during the electronics product prototyping phase include:
-
Rapid prototyping involves quick creation of functional product models to test ideas, refine product requirements, and provide project direction. Rapid prototyping is crucial for identifying design and user experience flaws early in the development cycle and avoiding costly reworkings at later stages.
-
Integration testing ensures that all system components (hardware and software) interact as expected. This step is essential for complex devices, such as those combining mechanical, electronic, and digital elements.
-
Usability testing revolves around evaluating how target users can interact with the product in different scenarios. Feedback from these sessions informs further scope refinements.
-
Performance and stress testing allow the prototype to be tested under extreme operational conditions in order to determine its durability and reliability. This ensures the product will function correctly under all expected real-world conditions.
-
Iterative improvements based on testing feedback help fine-tune the product’s design, enhance its functionality, and resolve any issues discovered before proceeding with custom hardware development.
Additionally, prototyping aids in defining requirements for your software engineers, who can begin developing embedded, web, and mobile applications, as well as cloud infrastructure, concurrently with hardware design activities. While not all product development electronics initiatives include traditional software development, the majority of modern electronic devices, ranging from microcontroller-based products to IoT systems, require some code to function properly.
To facilitate electronics product prototyping activities, several technologies can be used:
-
Development boards like Arduino, Raspberry Pi, and ESP32 are invaluable for building functional prototypes quickly and affordably. These boards are especially useful for IoT devices, as they can be combined with a variety of sensors and modules to simulate complex functionality.
-
CAD software assists in designing hardware components and enclosures. Specifically, you can look into tools like AutoCAD, SolidWorks, and Fusion 360, which allow precise modeling and adjustments before physical production.
-
Simulation software can be used to model electronics and interactions before physical prototypes are built. Tools like MATLAB/Simulink and LabVIEW help simulate both the hardware logic and the embedded software effectively.
-
Cloud-based IoT platforms, such as AWS IoT, Microsoft Azure IoT, and Google Cloud IoT, provide robust environments to simulate and test how devices will perform when connected to a network. They offer valuable insights into data handling, device management, and system scalability.
-
Low-code and no-code development platforms help create the software part for electronics products without extensive and expensive coding. Some examples of such platforms include Node-RED, Mendix, or Microsoft PowerApps, which are particularly useful for building user interfaces and integrating with cloud services.
After completing the prototyping and PoC phases, finalize the detailed functional and non-functional requirements documentation. This should include all validated user needs, system capabilities, and performance metrics.
For a real-world example of how prototyping helps gather and fine-tune requirements for custom electronics design, check out our case study detailing the development of an eye-tracking technology solution for neurological research.
Step 3: Custom hardware module and enclosure design
The design of custom hardware modules and enclosures is a critical stage in electronics product development, which involves several activities:
-
Schematic design. During this stage, electronics product design engineers create detailed circuit diagrams that specify the electrical components and their interconnections. For this, they use an array of tools, such as Altium Designer, Cadence OrCAD, and Autodesk Eagle. The designed schematic diagrams serve as blueprints for printed circuit board (PCB) layout and simulation.
-
PCB layout and simulation. These activities are focused on designing the physical layout of PCBs used in electronics product design and development. Specifically, we’re talking about placing components and routing traces in a way that will minimize signal interference and ensure optimal electrical performance. A company providing electronics product design services may use different tools for PCB layout design and simulation, including KiCad, Altium Designer, and Mentor Graphics. This stage of custom hardware design produces several deliverables, including gerber files ready for manufacturing and detailed simulation reports that demonstrate the PCB’s performance under various electrical stresses and scenarios.
-
Field-programmable gate array (FPGA) development. FPGAs can be used in products that require high-speed or complex digital processing. FPGA development entails programming these devices to perform specific functions such as digital signal processing, data management, and interfacing with other hardware components. There are several programs that facilitate FPGA development, such as Intel Quartus, Xilinx Vivado, and Microsemi Libero IDE. This phase of custom hardware development concludes with the preparation of FPGA configuration files and test reports detailing the FPGA performance.
-
Design for manufacturing (DFM). Electronics product design specialists will help you optimize all designs, validating that they are easy and cost-effective to manufacture. They’ll adjust PCB layouts, component placement, and enclosure designs to match the manufacturing capabilities at a selected facility and simplify device assembly. While most PCB design tools provide DFM analysis capabilities out of the box, your electronics product design partner may recommend using standalone solutions like Valor DFM from Mentor Graphics. Following the DFM stage, you’ll have revised PCB and component designs for manufacturing, advancing further in the electronics product development process.
-
Enclosure design and modeling. Designing physical device cases is particularly important in consumer electronics product development, where aesthetics and functionality take center stage. Enclosure design may also be subject to different regulatory requirements, such as FDA, REACH, RoHS, and CPSC, among others. When designing custom enclosures that house an electronic product, your technology partner may use tools like Autodesk Fusion 360, SolidWorks, and PTC Creo to create 3D models, prototype images, and specifications for materials and manufacturing processes. It is also recommended that you prototype enclosures using 3D printing software and CNC machining and test their fit, form, and function, as well as their resistance to temperature, pressure, and other conditions under which the product will operate in real life.
The stages described above not only ensure that the electronic modules are optimally designed for performance and production, but also that the product is appealing and durable in terms of physical and user experience.
Step 4: Embedded software development
Not all electronics products require embedded software. However, for those that do—ranging from simple household appliances to complex industrial systems—embedded software development is a crucial phase that ensures the functionality and user experience of the final product.
Embedded software can vary widely based on the complexity of the task and the processing capabilities of the device:
-
Bare-metal firmware is employed in simple electronic devices that do not require an operating system and lack computing resources or power capacity to run real-time or general operating systems. Some examples of such devices include microcontroller-based wearables and smart sensors. Bare-metal firmware’s sole purpose is to control hardware components and perform narrowly defined tasks, such as collecting sensor data. This type of embedded software is often developed using the C programming language.
-
Real-time operating systems (RTOSs) are necessary for devices that require reliability, real-time responsiveness, and concurrent processing (think medical devices, automotive electronics, and other safety-critical applications). In electronics product design, FreeRTOS, VxWorks, and Zephyr are popular choices for creating applications that require real-time performance.
-
General operating systems like Embedded Linux, Windows Embedded, and AOSP power more complex devices that offer a broad range of functionalities, such as smart home controllers or advanced robotics. They support advanced applications, networking, user interfaces, and multitasking environments. Additionally, operating systems help manage hardware resources and provide security features, making them suitable for the Internet of Things devices.
-
Middleware is common in devices that need to connect and communicate with other hardware or software systems, such as IoT devices. Acting as a bridge between different software solutions and hardware components, middleware encompasses communication protocols, device management instruments, and libraries for specific functionality, such as Wi-Fi or Bluetooth support. Some commonly used middleware development technologies include MQTT, AMQP, DSS, and custom-written APIs.
-
Embedded application software is found in devices that feature user interfaces and complex interaction models, such as consumer electronics with touchscreens or industrial equipment with human-machine interfaces (HMIs). Commonly referred to as embedded interfaces, these applications enhance user interaction through graphical UIs, touch input, and connectivity features, making products accessible and convenient to use. To create embedded applications, electronics product development engineers use various technologies, from Crank Storyboard to Embedded Wizard and Qt for embedded systems.
The development process for embedded software in electronic products necessitates careful consideration of the device’s intended functionality, user interaction, and connectivity requirements. By aligning the software development approach with these factors, businesses can ensure that their products meet both performance and user expectations.
Step 5: Pilot production and validation
The pilot production and validation stage helps test the manufacturing process, components, and assembly methods on a smaller scale to ensure everything works as intended before ramping up to mass production.
The process spans several stages:
-
Initial setup with a manufacturing partner. The first step is to identify and establish a relationship with a hardware manufacturing company that can meet your project’s specific needs. This includes ensuring that they have the right capabilities and certifications, particularly for products that require adherence to certain quality or regulatory standards.
-
Limited production run. Once a manufacturer is selected, a limited number of PCBs and enclosures are produced. This initial batch is critical for validating the design specifications, manufacturing consistency, and identifying any potential issues that weren’t apparent during the prototyping phase.
-
Comprehensive testing. During pilot production, specific tests are conducted to ensure that all hardware components perform according to expectations. This includes electrical testing of PCBs, fit and function tests for enclosures, and environmental testing to simulate real-world operating conditions.
-
Embedded software integration. This stage of the electronics product design process involves loading and testing the embedded systems onto the hardware to verify software and hardware integration. It’s vital to check that the software interacts correctly with the hardware, particularly for devices relying on real-time operations or complex user interfaces.
-
Iterative refinements. Based on the outcomes of the performed tests, modifications may be necessary. Most often than not, several rounds of iterations are necessary to ensure optimal performance and finalize your product for mass production, depending on the complexity of the product and the issues encountered during pilot testing.
-
Validation for scale. The final part of pilot production is validating the product design and manufacturing process for scale. This means ensuring that the product can be manufactured reliably, at scale, and within cost targets. It also involves finalizing the assembly line setup and worker training to prepare for full-scale production.
The pilot production and validation phase is essential for identifying and mitigating risks before full-scale production begins, thereby saving time and reducing costs associated with post-launch issues.
Step 6: Manufacturing and certification
After successful pilot production and validation, the next step is to transition to full-scale manufacturing. It requires careful planning and oversight, particularly when production is outsourced to countries like China, while your electronics product development engineers are based in America or Europe.
Here’s what you need to do to sail through mass production:
-
Carefully choose manufacturers that not only have the capabilities to meet your production needs but also possess a strong track record of reliability and quality control. It is essential to verify that they adhere to international manufacturing standards.
-
Establish clear communication channels and regular updates. For this, you can utilize technology for virtual meetings, real-time updates, and progress tracking. Sometimes the best way to avoid costly errors and accidents is hire local liaisons or quality control firms to act as your eyes and ears on the ground, ensuring that your specifications are precisely followed. Some companies that provide electronics product design services may offer to send their specialists to production facilities, assuming the role of a product owner.
-
Implement efficient quality control systems that align with both local and international standards. This includes detailed quality checks at various stages of the manufacturing process to identify and address issues early.
-
Create a feedback loop that allows for continuous improvement based on ongoing testing and quality checks. This way, you can continue refining the product even during the manufacturing phase.
-
Develop a well-organized logistics plan to manage supply chains efficiently. This includes handling of materials, managing inventory levels, and ensuring timely delivery of components and final products.
A few words about managing the manufacturing process from afar. We strongly recommend that you schedule regular visits to the manufacturing sites by project managers or engineers from the electronics product design team. By doing so, you will maintain a strong presence and ensure that the manufacturing process aligns with your company’s standards.
It is also important to conduct regular compliance checks to validate that all local and international regulations are met. This includes environmental regulations, labor laws, and safety standards.
Lastly, you should wrap your head around some common certifications for electronics products:
-
FCC certification is required in the United States for electronic products that emit radiofrequency. It helps ensure that electromagnetic interference is within approved limits.
-
CE marking is mandatory for products sold in the European Economic Area, indicating compliance with health, safety, and environmental protection standards.
-
RoHS compliance restricts the use of specific hazardous materials found in electrical and electronic products within the European Union.
-
UL certification provides a baseline assurance of a product’s safety for American markets. It is often considered essential for consumer electronics.
-
Various ISO standards may apply to electronics product development, depending on the type of solution you’re aiming to create. These may include ISO 9001 for quality management systems or ISO 14001 for environmental management.
Please note that, while helping you navigate the electronics product design and development process, a third-party company is not responsible for obtaining these certifications for you. However, they can consult you on how to meet the regulatory requirements while helping you optimize the associated costs.
Step 7: Product launch and post-launch support
The final phase of your electronics product design and development project revolves around bringing your solution to the market or implementing it within your organization, incrementally or at scale, depending on what your objectives are.
For this article’s purpose, we’ll describe the activities associated with commercial product launches and how your electronics product design partner can assist you on this journey:
-
Market preparation. Together with your technology partner, you need to prepare the market for your new product through comprehensive market analysis, strategy development, and demand generation. This includes identifying target markets, understanding competitive dynamics, and planning effective entry strategies.
-
Marketing and promotional activities. You need to develop marketing collateral that highlights the unique features and benefits of your product. These may include digital content, product datasheets, user manuals, and promotional videos.
-
Launch events. Organizing webinars, trade shows, and virtual launch events can be coordinated with the help of your design partner to maximize exposure and engage directly with potential customers and industry stakeholders.
-
Distribution channels. An experienced electronics product design and development team can help you establish and optimize distribution networks, ensuring that your product is accessible to your target audience, whether through online platforms, retailers, or direct sales.
Releasing your solution to the market does not mark the end of the electronics product development cycle. It is recommended that you continue working with your technology partner to improve and enhance your product:
-
After the product launch, it is crucial to gather and analyze customer feedback. A third-party company can set up systems to collect, monitor, and analyze customer reviews and usage data to identify potential areas for improvement.
-
Based on the collected feedback, your electronics design partner can assist in planning and implementing product updates or iterations. This includes both software updates and possible hardware revisions, if needed.
-
Offering ongoing technical support can significantly enhance customer satisfaction and loyalty. Your technology partner can provide training for your support team, develop troubleshooting guides, and even manage customer support services on your behalf.
-
As regulations change, the product may need updates to remain compliant. A third-party design company can help monitor regulatory changes and guide you through necessary updates to certifications or product specifications.
Common electronics product development challenges and how to overcome them
Developing an electronics product is a complex and multifaceted endeavor, fraught with potential pitfalls that can derail even the most well-planned projects. Understanding these challenges and preparing strategies to mitigate them can significantly increase your chances of success.
Scroll down to discover some of the common electronics product development pitfalls along with practical ways to handle them.
Scope creep
-
Challenge: Scope creep occurs when new elements or features are added to a product’s scope after the initial planning phase without adjustments to time, resources, or budget. This can lead to project overruns and resource depletion.
-
Solution: Maintain strict scope management and engage in regular stakeholder meetings to ensure alignment and avoid unnecessary expansions of the project’s scope. Utilizing an Agile development methodology can also provide flexibility while keeping the project’s focus on delivering value incrementally.
Overlooking technology roadblocks
-
Challenge: Failing to anticipate technological challenges or roadblocks can lead to significant delays and cost overruns. For example, underestimating the complexity of integrating different systems or components might result in last-minute design changes.
-
Solution: Conduct thorough feasibility studies and prototype testing early in the development process. Engage with technical experts and consultants who can provide insights into potential technology roadblocks before they become critical issues.
Failure to manage costs
-
Challenge: Cost overruns are common in electronics product development due to unexpected expenses, scope creep, or misestimated resources.
-
Solution: Develop a detailed budget that allows for contingencies. Regular financial reviews and cost tracking can help manage expenses effectively. For a detailed understanding of cost factors specifically related to IoT projects, consider insights from the ITRex team’s analysis on how much IoT costs, which discusses various cost implications and challenges.
Inadequate testing
-
Challenge: Insufficient testing can lead to products that fail to meet market needs or, worse, products that malfunction.
-
Solution: Implement a comprehensive testing strategy that includes various types of testing, such as unit testing, integration testing, system testing, and user acceptance testing (UAT).
Regulatory and compliance Issues
-
Challenge: Electronics products often face strict regulatory requirements, and failing to comply can lead to legal issues or product recalls.
-
Solution: Stay informed about the regulatory standards applicable to your product and engage in compliance testing during the early stages of development. Consider working with regulatory consultants who can provide expertise in navigating complex compliance landscapes.
Supply chain disruptions
-
Challenge: Supply chain issues, such as delays in component delivery or quality issues, can significantly impact your production schedule.
-
Solution: Develop strong relationships with multiple hardware suppliers and consider alternatives for critical components. Implementing robust supply chain management practices can help anticipate disruptions and react swiftly.
Partner with ITRex on Electronics Product Development
At ITRex, we understand the complexities and challenges associated with developing cutting-edge electronics products.
With our dedicated in-house R&D department, expertise in IoT and AI technologies, and a team of seasoned hardware design and embedded system development experts, we are uniquely equipped to bring your innovative ideas to life.
-
Tailored expertise and support. Our focused approach allows us to fully immerse ourselves in each project, acting as an extension of our clients’ teams. This close collaboration enables us to propose the most flexible and cost-effective solutions, tailored to your specific needs. We pride ourselves on our ability to manage intricate projects, ensuring that every aspect, from initial design to final product launch, is executed to the highest standards.
-
Comprehensive services. ITRex offers a full spectrum of services that cover the entire lifecycle of electronics product development. Whether you need assistance with navigating the complexities of hardware design, managing relationships with manufacturing partners overseas, or ensuring compliance with global regulations, our team is here to support you. After your product goes live, we continue to offer post-launch support, helping to collect and analyze user feedback, implement product updates, and maintain the product throughout its lifecycle.
-
Strategic partnership. Our goal is to ensure that your electronics products not only meet market demands but also exceed them. By leveraging our expertise in innovative technologies and comprehensive support services, we help you mitigate risks, manage costs, and achieve a successful product launch.
