Mini lesson

What hardware development actually takes


By John Teel4 min read

The question I hear more than any other is some version of "how long is it going to take me to develop and launch my product"

Here's the honest, stage-by-stage version, based on all of the products I've seen successfully make it to market.

Proof of concept: 1 to 3 months

You're working with dev kits and breadboards, plus off-the-shelf modules. This stage moves fast because the whole hobby ecosystem exists to serve it.

All you get out of it is proof that your concept works, and that's still a long way from a finished product.

Your first custom PCB: 4 to 9 months

This is where timelines start surprising people. Every board revision is its own loop: you design it, get it fabricated and assembled, then test and debug what comes back.

Each loop realistically takes 4 to 8 weeks, and revision one always has problems, because finding problems is its job.

Plan on two or three revisions and you'll rarely be wrong.

Enclosure and form factor: overlaps, but adds months

This stage covers CAD design and 3D printed iterations, plus the fit problems you can't see on a screen. It also feeds back into the electronics, because the enclosure and the PCB constrain each other.

Getting into your real form factor is when you can finally put the product in front of real users, and their feedback often changes your requirements.

You actually want that loop, because it's far cheaper to change direction here than after tooling.

The production redesign: 3 to 6 months

A working prototype and a manufacturable product are two different designs.

This stage means designing for automated assembly, sourcing every component at production volumes, adding test points and a test procedure, and working the design down to your target cost.

Founders consistently mistake this for a cleanup pass, but it's a real engineering phase.

Certification: 1 to 4+ months

The testing itself takes weeks. The risk is failing, because a failed round means redesigning and then prototyping and testing all over again.

Designs that weren't built with certification in mind regularly fail their first attempt, so unless you've been designing for it all along, budget for one failure.

Tooling and pilot production: 3 to 6 months

Injection molds take two to three months to cut before you see first samples, and first samples always need adjustments.

After that comes a pilot run, and then fixing whatever only shows up when a factory builds hundreds of units instead of you building two.

Add it up honestly, and if every stage goes right the first time, a first product takes at least 12 months.

But stages rarely go right the first time, especially when you're figuring each one out as you go.

Maybe a wireless protocol turns out wrong at month nine, or your board fails certification and goes back for redesign. Or the factory can't build your prototype at volume, and each of these sends you back through a stage you already paid for.

So that's how a 12-month product turns into a two or three year product, or more. Most of that extra time is the same work getting done twice.

You can't compress the physics, because fab times and mold cutting take what they take, and test labs have queues you can't skip.

Repeated work is the part you can compress, and that comes down to being properly prepared for each stage before you get there.

Experienced eyes at each stage, catching problems before you build them, are what keep a product near that 12-month floor instead of drifting toward year three.

Take another look at that stage list, because it spans validation, circuit design, layout, mechanical, manufacturing, certification, sourcing, and production.

Each stage has its own way to cost you six months, and no single engineer specializes in all of them.

So you've got a few options for covering all of that.

You can learn each stage as you reach it, which works fine if your timeline can absorb the learning curve. Hiring specialists stage by stage works too, as long as your budget can keep up.

Or you can join my Hardware Academy and get a team of engineers and product experts who've been through every one of these stages. They'll help you get each stage right the first time, and they'll stay in your corner however many years your product takes.