The 5 Steps of Product Development for a New Electronic Hardware Product

 

The new product development process for an electronic product (or any product) is by no means simple. It’s a pretty overwhelming task especially for those with limited resources such as entrepreneurs, makers, start-ups and small companies.

However, the process can be simplified by breaking it down into five steps. The steps summarized below will get you to the point of having a fully functional prototype.

There are many other steps to getting a product to the point of being manufactured in volume and sold to the general public.

NOTE: If you're serious about developing a new electronic hardware product then download our free cheat sheets - 15 Steps to Develop Your Electronic Product and Summary of the Costs to Develop Your Electronic Product.

So the five steps for the development of an electronic product are:

Step #1 – Design the Circuit Schematic

The end goal of the electronics design is the creation of a Printed Circuit Board (PCB). The first step of making a new PCB is the creation of the schematic circuit design. A schematic is similar to a blueprint for a house.

Designing the schematic circuit first includes early research to select the best topology and most affordable components.
 

Circuit Design Schematic

A schematic circuit diagram is the first part of designing a new electronic circuit board.

It may also include running simulations and/or breadboarding (used only rarely in modern electronics).

If you plan to design the electronics yourself, and you need electronics design software that is not only really affordable, but also powerful and intuitive, then definitely check out DipTrace. I’ve personally used it for years with fantastic results. It’s easy to learn but powerful enough to handle the most complex designs.

Step #2 – Design the Printed Circuit Board (PCB) Layout

Using the same software package as in step #1, the designer now creates the PCB layout.

A portion may be automatically routed but most boards require manual routing for optimum performance.  The PCB layout is extremely sensitive for power and RF circuits (Bluetooth, WiFi, GPS, etc) and mistakes on the PCB in these areas are common.

PCB Layout

After the schematic diagram is done it’s now time to create the PCB layout.

When the PCB layout is complete the design software (for example, DipTrace) will tell the designer if the PCB matches the schematic.  It will also check wire widths, trace spacings, etc. to ensure the layout meets all of the rules for the particular PCB fabrication process being used.

Before beginning the PCB layout it will be necessary to obtain all of the specification from your PCB manufacturer for their process. Each PCB manufacturer has different specifications for their process.

Once the PCB design is completed it’s time to send the data off to a PCB shop for prototyping.

For moderately complex products a few prototype circuit boards will cost around $1k to $2k. You can expect the boards to arrive in about 1-2 weeks (without paying extra for rush service).

Step #3 – Evaluate and Debug the Prototype

Once the first prototype comes back it will now need to be evaluated and if any problems are found, those will need to be debugged.

Examples of blank (before components are soldered on) Printed Circuit Boards (PCBs).

Hopefully there are no problems, but that’s extremely rare, and there are almost always at least a couple of issues.

Debugging a new circuit is a difficult step to forecast, because until you know what the problem is, you can’t estimate how long it will take to fix it.

Step #4 – Program the Microcontroller

Almost all electronics products today have some kind of microcontroller that acts as the brains for the product.

These are almost always programmed in a computer language called “C”.  If the program needs to be super efficient or fast then parts of it may be done in assembly language.

Sometimes the programming will be done by the same person that designed the circuit, but many times a software specialist is brought in to do the programming.

Step #5 – 3D Modeling

This is almost always handled by a different engineer than who did steps 1 thru 4.

In the beginning all you really need is a 3D modeling expert, especially if you have a good vision of what your product should look like.

Eventually you may want to hire an industrial design engineer to really make it look good.  For example, industrial designers are the engineers responsible for making Apple’s products look so cool.

Either way make sure whoever does the 3D model design has experience with injection molding technology. 3D printing is used for low-volume prototyping, but injection molding is used for high-volume manufacturing. It’s a common mistake for 3D designers to create a model that can be 3D printed but not injection molded.

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This is just a brief summary of the new product development process for an electronic product. If you are looking for more in-depth details then be sure to check out the Ultimate Guide on How to Develop a New Electronic Product.
 

NOTE: If you're serious about developing a new electronic hardware product then download our free cheat sheets - 15 Steps to Develop Your Electronic Product and Summary of the Costs to Develop Your Electronic Product.

Have any questions? If so, feel free to contact us. We love helping entrepreneurs and always reply to questions.

 
 

 

Leave a Reply 3 comments

John Burrill - November 30, 2014 Reply

I’m really surprised that the design doesn’t start with the mechanical layout-with the positioning of the mounting hole locations and interface components.
Aside of prototypes, I’ve seen very few electronics components that were self-contained packages.

Keith - November 1, 2014 Reply

I find that I have followed this process several times in the past only to have to completely redesign the PCB to fit into to case that is required for ergonomics and functionality.

Now, I take the approach of designing a basic case first, and the PCB is usually the more flexible of the facets in the product. Once I know what shape and size the PCB needs to be, then I can work on the detailed layout.

For many products the PCB is quite a bit smaller than the case, resulting in little interaction between the mechanical design and the PCB layout, but for others they are coupled, so the shape and layout may be affected.

    John Teel - November 2, 2014 Reply

    Thanks for the comment Keith. It’s important that you have a rough idea on the size of your product and you don’t want the PCB layout designed with no limits at all on size or shape. Some product inventors know exactly the size they want, and in those cases I work backwards from their case size. Some projects don’t have the size specified so clearly and the PCB size is a bit more flexible. Finally, some projects want a size that is too small for the electronics, so the size usually has to be increased to accommodate the required size PCB. If small size is super critical then advanced PCB production techniques like blind vias and high layer counts can be used.

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