Steps to Build electronics prototypes  Prototype PCB Firmwares

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Methodology for manufacturing electronic prototypes

When it comes to electronic prototypes, we have identified that one of the main concerns for inventors is finding manufacturers in China capable of producing thousands of electronic boards (PCBs). While this step is crucial for the future health of the business, prioritizing this manufacturing process before developing functional electronic prototypes will doom your project to failure.

Remember that the goal of a functional prototype is not just to demonstrate technical feasibility. Throughout its design and manufacturing process, it is essential to iterate and learn enough to achieve the most optimal functionality and future production.

 

The development of electronic prototypes, just like in software development, can achieve the same function through hundreds of different approaches. However, making the right choices in the development strategy will critically impact the future cost of the product, as well as its potential for growth and the integration of new features necessary to compete in the market.

Parts of an Innovative Electronic Prototype

The development of an innovative electronic prototype is divided into two main hemispheres: Hardware and Firmware.

Which comes first, Firmware or Hardware development?

Logically, if firmware is the software that controls and enables the functionality of the electronic hardware within the prototype, it makes sense to first complete the development process of the physical components, including the PCB, selection of controllers, peripherals, and any other necessary elements as part of the hardware architecture of an electronic prototype.

On the other hand, progressing too far in hardware development can lead to a waste of resources, as it is very common in the development of innovative electronic products to encounter new hardware requirements needed to ensure compliance with the functional requirements of the electronic prototype in question.

After developing more than 100 electronic prototypes with varying levels of complexity, at Let’s Prototype, we have developed an effective method to coordinate tasks throughout the design and manufacturing of electronic prototypes.

Step-by-Step Process for Functional Electronic Prototypes

Step 1: Defining Functional Requirements

The starting point for beginning the development of any prototype, regardless of the engineering disciplines involved, is to carefully gather requirements and document the results.

In most cases, the requirements gathering focuses on the key functions of the prototype, meaning those that address the market problem the new device aims to solve. This approach can sometimes jeopardize the future development of functional prototypes, as it may lead to the wrong choice of the prototype's core technologies.

Using the analogy of construction, a sector we all understand. If we gather the requirements for a single-story house and later the client wants to add an extra room, it likely won’t be a major issue since the foundation will support this additional load. 

On the other hand, if the client, after the first and only planned floor has been built, requests the construction of two additional floors, it will likely be impossible or require demolishing the existing structure to reinforce the building's foundation. 

The same happens in technology. In the custom electronic product development industry, we call this: technology scalability. It involves selecting technologies (both hardware and software) that are robust enough to allow the prototype to grow in functionality without the need to discard the technological advancements made in the earlier versions.

It is crucial to understand the business development strategy intended for the prototype during requirement-gathering meetings. 

Yes! Even though our goal is to develop a functional electronic prototype, we must understand the anticipated business needs at each stage in order to establish a product development strategy that supports and enables the achievement of business objectives.

Well-executed functional requirements gathering not only defines the functions but also allows them to be organized into versions and complexity levels. This version-based approach enables the inventor to control initial investments, reduce the perceived risk for potential investors, shorten time-to-market, and conduct prototype functionality testing.

In this first step, the experience in electronic product development that the professional has accumulated makes a difference. At Let’s Prototype, we don’t just follow client comments and requests. From the very first meeting, we strive to add value by contributing ideas, simplifying functions, and conducting a preliminary analysis of the technical feasibility of the proposed expected functionalities in the prototype.

Step 2: Defining Use Cases and Business Logic.

fabricación de prototipos electrónicos

Many electronic prototype development companies confuse the gathering of functional requirements for the future product with the writing of use cases for a functional prototype.

Requirements Gathering: Writing the key functions of the expected functional prototype. It focuses on defining which functionalities are necessary and how these functions will appear in the different versions of the electronic prototype.

 

Use Cases of a Prototype: This document summarizes the behavior of an electronic prototype. It provides a written description of how the machine operates in different scenarios. It is crucial for the client to validate this document before starting the development of the electronic prototype, as requirement gathering often includes technical terms that may affect the client's proper understanding. Utilizing mapping techniques and images is very useful to avoid discrepancies between the client's vision and the final product.

In electronic prototype cases that include screens, it is highly recommended to consider the appearance of screens at each stage of the use case. As a best practice in writing use cases, it is advisable to divide processes into stages or product states. This approach helps the custom Firmware development team define critical variables in the source code structure.

Step 3: Preliminary Hardware Architecture Design.

ejemplo de prototipos agrotech

The preliminary hardware architecture is a valuable process in the development of electronic prototypes. It involves the initial planning and exploration of electronic components necessary to achieve the various functions listed in the requirements gathering, which must also be compatible with the definitions outlined in the functional prototype use case document.

When it comes to electronic prototypes, at Let’s Prototype, the first thing we do is analyze the electronics required for the prototype, and then develop the circuits on paper and in digital format.

That’s right, we sketch out the different logic flows or circuit diagrams on paper. This way, the entire expert team in the field can provide input on the most optimal ways to reach the solution.

This phase includes the selection of electronic components. It is crucial for the electronic engineering team to identify components that are widely available in the market, meet the needs of your prototype, and are economically viable options according to the target price of the future product in the market.

It is a difficult balance to achieve, but it is part of our daily work. 

Before manufacturing the first PCB, we experiment with connections and components on a breadboard to identify potential faults or incompatibilities between the selected components. In this phase, we achieve the electronic functionality of the prototype, refining all the details to ensure it behaves as expected.

Most electronic product development companies make the critical mistake of skipping this step. They assume the functionality of electronic schematics and proceed directly to manufacturing the first version of the PCB without validating its functionality and component compatibility. This mistake results in a loss of time and money—resources that are often scarce in the design and manufacturing of innovative electronic prototypes.

Step 4: Development and Validation of Critical Functions in Firmware.

Using the functional requirements document of an electronic prototype as a guide, the firmware programming should begin. It is a mistake to assume that this first version will be final. It is usually subject to multiple revisions, making it essential to understand the real objective of this stage: demonstrating that the components can coexist and that, with minimal resources, the main functions of the prototype can be achieved.

According to our experience at Let’s Prototype, we refer to this first version of the firmware as control software. It is a firmware version that must be capable of controlling the components that will coexist on the PCB, as well as the main peripherals required to meet the functional requirements.

Among the common mistakes made by firmware development experts are: not maintaining a firmware version management system, working with local code—meaning not using an environment that allows for the shared evolution of the firmware code and its continuous auditing—and failing to properly document the development both within and outside the developed firmware.

Based on our experience with dozens of developed firmware solutions for our electronic prototypes, we highly recommend working with technologies that are widely adopted in the market. Leveraging the work of the community, staying connected with it, and contributing value are key to developing high-quality firmware and maximizing the efficiency of the development process.

Step 5: PCB Prototype Design and Manufacturing.

The previous stages provide crucial insights for designing the first version of a PCB for an innovative electronic prototype.

Once the circuits are completed and validated, we focus on designing a printed circuit board (PCB) while minimizing the size of the electronics. At this stage, we can manufacture the first unit by etching the circuit onto a copper board, applying the solder mask resin, and soldering the components.

After completing the manufacturing process of the first unit, the prototype moves into the testing phase. Typically, this stage prompts the aesthetic redesign of the prototype, allowing its components to become smaller and more compact.

You will find thousands of options for manufacturing your PCB in series. You could go to China or other industries where mass production prices are highly competitive. However, before taking this step, you will likely need small batches or pre-series to validate the product in the market, present it to investors, or showcase it to potential industrial partners. In this case, Let’s Prototype remains your ideal partner. If you need between 10 and 100 electronic boards, we can manufacture them in our laboratory with full quality assurance. For orders exceeding 100 and up to 10,000 units, we can source them through Let’s Prototype’s strategic partners.

The first version of the PCB, combined with the first version of the firmware obtained in stage No. 4 of our method for developing electronic prototypes, will reveal errors that can be immediately corrected through external connections, component replacements, adjustments in the control software, and other quick fixes. These will help document the necessary changes for the design and manufacturing of the final PCB.

Step 6: Integration of Hemispheres – Hardware and Firmware.

Using the transformed PCB, customized and refined through agile methods, we face one of the most critical stages in the development of electronic prototypes.

The objective of this stage is to integrate both hemispheres: hardware and firmware into the manufactured beta prototype. In this scenario, all types of tests and adjustments must be performed until achieving harmony between both hemispheres.

The experience of the electronic prototype development company is key. There is a list of best practices for the design of the first version of the PCB that will help prevent unnecessary delays during this stage of functionality testing and adjustment.

Preparation for using pin extensions, exposing extra pins, overprotection for energy consumption, and oversizing spaces for manual connections are some of the useful practices to maximize efficiency during the hemispheres integration phase in electronic prototypes. The goal is to avoid halting the process due to common and natural errors in the first version of the PCB.

Step 7: Verification of Functional Requirements in the Electronic Prototype.

The natural chaos of the integration stage can be frustrating for novice developers of functional electronic prototypes. Once the first version of the physical electronic solutions and the firmware has been stabilized, the prototype must undergo various tests. At this stage, the most useful verification document is the compilation of use cases.

In our electronic prototype laboratory, we have learned that the key figure in this stage is the client. It is essential to involve the client in the testing cycles of the electronic prototype’s functionality, as they will be the best critic of the prototype’s performance.

Client involvement in the verification stage of functional prototypes with electronic components helps prevent the late emergence of new requirements and, following the construction analogy, avoids the need for radical changes that could compromise the prototype development timeline.

Step 8: Power Optimization and Final Firmware Optimization.

At Let’s Prototype, we frequently develop custom wearable device prototypes and IoT prototypes. In this type of prototypes, power consumption is often a key factor in making the prototype truly functional.

Smart sports wearables and agrotech prototype examples that must operate in harsh conditions without electrical power are some of the cases where we have faced these challenges.

The initial battery autonomy strategy must be defined during the R&D process of a prototype. For this reason, at Let’s Prototype, before manufacturing an electronic prototype, we offer this service to inventors and the innovation departments of our corporate clients.

What is involved in the energy autonomy analysis of an electronic prototype?

Before starting the manufacturing of the first version of a prototype's PCB, it is crucial to study the individual power consumption of the peripherals and electronic components within the prototype. This information is combined with various requirements and use cases, where the target energy autonomy of the electronic prototype must be defined for it to be considered functional.

For our non-expert inventor clients, we frequently use the analogy of household plumbing systems. A water tank has a specific capacity, and if we want to rely solely on the tank’s water supply, we must first study the typical consumption at each dispensing point and the expected usage cycles. With this information, it can be determined whether the planned tank in the project is sufficient to support the intended use.

Something similar happens with energy consumption in prototypes. For this reason, it is crucial to properly document the usage objectives. With this information, during the development of an electronic prototype, we conduct validations at various stages.

The validation stage on the handcrafted circuit on a protoboard is crucial, as it provides valuable insights for firmware development, where activation cycles of different components are programmed, and various strategies are implemented to minimize energy consumption.

The prototype's dimension requirements, its geometry in the battery installation area, prototype weight, and compliance with future regulations are some of the key variables that must be carefully considered when defining the energy consumption strategy of an electronic prototype.

Step 9: Industrialization Strategy for Electronic Prototypes.

As you know, the industrialization process of a prototype is the conversion of functional test units into a marketable product. Various manufacturing techniques and assembly procedures are involved in this process.

Attention! At this stage, you will have already demonstrated the potential of your product and, of course, its technical feasibility. Now, the objective is to minimize the costs associated with the product manufacturing process and ensure the protection of your intellectual property.

In electronic prototypes, many factors coexist that can impact these two objectives. Below, we list some common risks and solutions from our laboratory:

Objective No.1: Minimize Costs in the Manufacturing Process of Innovative Electronic Products.

Hardware Design and Geometries: To save money in the prototyping process, many inventors turn to prototype manufacturing companies with little experience in the full development process. In these environments, it is often overlooked that product assembly has a significant impact on the manufacturing cost of the products. The method of inserting and mounting the PCB inside the prototype, connector placement, and the use of discontinued electronic components in the industry are often some of the focal points of conflict in this process.

Yes! What you saved in design and manufacturing your electronic prototype, will turn into a problem that can lead to the commercial failure of your product due to the extremely high costs associated with manufacturing each unit.

Electronic Product Regulations: The development of cheap electronic prototypes often leads to conflicts in the certification process with current regulations that affect the ability to commercialize electronic products. The lack of knowledge about these standards and cost-saving measures in CE Marking research, leads to the need for substantial changes in prototypes at very advanced stages, forcing you to bear extremely high costs to transform the prototype and comply with existing regulations.

Objective No.2: Protect Intellectual Property.

Firmware Installation Methods in Electronic Prototypes: We understand that the intellectual property of your electronic prototype is key to creating barriers to entry for new competitors. If you make it too easy, within hours, they will copy your product, and you will see it on the market. Even if you have a patent, you will face a very high risk if the necessary measures are not taken from the electronic prototype manufacturing process.

As you already know, for your innovative electronic product to function properly, the hardware electronic components coexist with the firmware, that is, with the product control software. Therefore, in the industrial manufacturing process, it will be necessary to install this software in the product. At some point, you will need to share your software and hardware solution with the factory, meaning the technology will no longer be solely in your hands.

There are different methods that allow you to reduce the costs of this process while also maintaining control to prevent future manufacturers or collaborators in your project from manipulating and distributing the control software, which is ultimately the brain of an electronic prototype.

FAQ about Electronic Prototypes

El precio de un prototipo electrónico puede estar entre los 15.000€ y 30.000€ aproximadamente. El coste de los prototipos electrónicos depende del nivel de incertidumbre asociado a las funciones que se pretenden conseguir y a las restricciones que conviven en los requisitos funcionales. 

El desarrollo del firmware suele costar entre 10.000 € y 20.000 €. El coste del firmware suele representar el 70% del precio total de un prototipo electrónico. La buena noticia, es que la parte software de un prototipo electrónico, es escalable, mientras que la parte hardware no cuenta con esta oportunidad. 

O sea, cuando lances tu prototipo electrónico al mercado, cada vez que vendas una unidad, debes asumir el precio de fabricación de la PCB y la compra de los periféricos electrónicos. En cambio, el firmware es siempre el mismo y no requiere ningún coste por cada unidad vendida. La inversión necesaria para desarrollar el firmware de un prototipo electrónico, tiende a cero a medida que se venden unidades, por esta razón, se afirma que se trata de una inversión escalable.  

Although it is a common practice to save on electronic prototype manufacturing costs, in our experience, it is much more expensive in the long run. It is difficult to hold accountability for performance and often leads to overengineering, among other common mistakes in electronic prototype development.

The development of electronic prototypes can take approximately 3 to 6 months. The manufacturing times of a functional electronic prototype, as well as its actual costs and final quality, are closely related to the depth of the research and planning cycle beforehand.

Yes. Although many advisors encourage the protection of electronic products with Utility Models, this is often a mistake and a lack of commitment from these advisors. As long as there is innovation and it provides a competitive edge in the market, the product can be patented.

The minimum viable product of an electronic prototype could consist of a functional unit with reduced dimensions, whose features can be demonstrated without the need to design and manufacture a custom PCB or complete the final firmware development.

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