From concept to creation: The path to product realization 

Figure 1: The journey of an idea

Creating a product starts with solving a problem. An idea, inspired by a need or challenge, becomes a prototype that epitomizes innovation and creativity. This first prototype undergoes a feasibility test and is demonstrated as a proof of concept (POC). An idea becomes a prototype, then a market-ready product. However, even the best products eventually reach their end, whether through wear and tear, outdated materials, or new tech, ideally with minimal environmental impact.

This article looks at key optimizations in the development of electronic products using real-world examples. It targets mass-produced tangible electronic products. It aims to educate young engineers and help business professionals, such as CTOs, understand the importance of a qualified engineering team in transforming concepts into successful products.

Navigating the hurdles in product development

Transitioning a prototype to a real-world product involves many optimization challenges. The engineering team must recognize and prioritize these challenges to effectively manage resources and meet product specifications. The following diagrams illustrate how priorities are arranged for two use case examples.

Figure 2: Solar powered IOT Gateway use care

Figure 3: Hearing aid use case

Mechanical optimizations

Electronic products must fulfil the mechanical specifications for circuit boards, considering factors like size, shape, and placement of component. Engineers must choose appropriate components and handle placement restrictions while maintaining signal integrity with effective multi-layer PCB stacks and routing techniques. It requires expertise in both electronics CAD and mechanical CAD integration.

Design for sustainability: A core design principle

Sustainability in a product refers to its ability to endure over time. To achieve this, the product's design must address several challenges, some of which are discussed in the following table.

Figure 4: Fixed version 5V version

Figure 5: Adjustable version

Optimizing power utilization: A universal design priority

Electronic products are powered by utility grids, renewable energy sources, batteries, or energy harvesting methods, depending on the application. Design engineers must prioritize reducing power consumption regardless of the power source.

Cost optimization: The most demanding aspect of product development

Cost optimization takes precedence in product development, particularly in mass manufacturing. Cost optimization throughout the product life cycle, such as manufacturing, servicing, and disposal, should be considered while designing.  

Ensuring safety and security: A paramount concern

Products such as ATMs, access control systems, IoT, gateways, etc. require security measures to protect sensitive data. Implement appropriate techniques during the design stage to ensure required security levels and standards.

Examples:  

• Implement access passwords in firmware.
• Use secure protocols and encrypt data during communication and storage.
• Establish tamper-proof methodologies and tamper-detection mechanisms.
• Connect a BGA microcontroller's serial port to a GSM module with bottom-side pads through the inner layers of a multi-layer PCB, making it harder for a hacker to tap into the serial port and read data.
• Products may also require critical safety measures to reduce risks to humans and property. This includes techniques to improve security.
• Implementing effective surge protection techniques for power inputs and outputs is crucial. Additionally, apply static discharge protection for inputs that involve human interaction, such as keypads and touch screens.

Examples:

• Implement redundancy by including backup components or circuit boards.
• Establish default fallback states and quick stops for all moving machinery parts.
• Incorporate fault detection hardware, such as microcontroller supervisory chips and watchdog timers.
• Fix a limit switch to cut off motor power if it drives a slider beyond a set limit in case of a motor driver failure to reduce damages.
• Implement fail-safe techniques such as using a pulled-up input to detect an emergency stop switch press. This causes any connection failure between the switch and the microcontroller to trigger an emergency stop.
  
  

Figure 6: How a microcontroller works to ensure security

Design for ergonomics: A vital consideration

Ergonomics is the science of designing products to optimize human well-being and performance. It plays a pivotal role in shaping user experience, comfort, and engagement, aligning products with the natural capabilities and limitations of the human body.

Examples:

• The placement and size of buttons and touchscreens to accommodate diverse user demographics.
• The beep of a supermarket barcode scanner indicates a correct read without needing to turn and check the display. The laser beam helps align the reader easily, and factors like weight, size, shape, and table rest for easy grabbing support ergonomics.

Promote environmental resilience: An environmentally conscious design

Products must withstand environmental hazards. Enclosures should meet appropriate ingress protection (IP) levels, and designs should support maintaining this protection.

Examples:

• Using a sealed light pipe for an indicator LED to help maintain enclosure integrity.
• Vertically mount circuit boards to accumulate less dirt and condensation.
• Using a membrane keypad that provides better shielding.

Ensure adherence to compliance: A key aspect of electronic product design

Product designs must adhere to international compliance standards, such as EMI and safety. Design engineers must consider these requirements during the design phase to minimize iterations and achieve compliance.

Examples:

• Follow best practices in PCB design to minimize EMI and EMC, when high-speed data transfer and high-speed switching in power stages such as a PWM motor controller.
• Print high voltage warnings and symbols.
• Cover high voltage tracks on the PCBs with extra silk screen pours.

Futureproofing: Design for repairability and upgradeability

Design for easy repair and upgrade to extend the product's lifespan and reduce the environmental footprint associated with premature disposal and replacement. Modular design is one of the key techniques in this process.

Examples:

• Design the communication modem (GSM, Wi-Fi, etc.) as a pluggable module to allow easy replacement of faulty parts, reducing downtime. It also simplifies upgrades during technology shifts like moving from GPRS to LTE or GSM to LoRa. Though firmware updates are needed, this approach ensures that the product remains adaptable to technological advancements.

Design sustainable disposal: A commitment to environmental responsibility

Design an electronic product with end-of-life disposal for easier and safer disposal, with a low environmental impact. Ensure product compliance with environmental regulations such as RoHS (Restriction of Hazardous Substances), WEEE (Waste Electrical and Electronic Equipment) directives, and eco-label certifications like Energy Star and EPEAT.

Examples:

• Specify non-toxic and recyclable materials (ex. Lead-free Solder) for product manufacturing.
• Modular design can improve the reuse of certain parts and dismantling before disposal to improve disposal safety.
• Use standard and interchangeable components to improve reusability.
• Make it easy to remove items like battery displays, etc.

Case study: A real-world example

An electronic controller was retrofitted into an existing power distribution unit (PDU) for a leading telecom operator in Sri Lanka. This upgrade enabled remote ON/OFF control of underutilized telecom equipment across the country's telecom infrastructure facilities. The picture below is a 3D rendering of the actual circuit board designed.

Future proofing

We designed a PCB footprint to accommodate two distinct ethernet module types from different suppliers, allowing use of the other without hardware modifications if one becomes obsolete.

Safety

Optically isolated the microcontroller and related electronics from relays and chassis connections linked to battery-positive terminals in telecom use cases. This prevents accidental contact between the USB debug cable or laptop body, which is on battery negative (the circuit ground), and the chassis during troubleshooting and installation, avoiding dangerous battery short-circuiting.

Cost/environmental impact

The decision to retrofit an electronic controller into an existing PDU saved all the original parts, resulting in significant cost savings and a substantial waste reduction.

Fail-safe design

Utilized the normally closed contacts of relays to power telecom devices. Added a power switch for quick device fallback to default so that all telecom equipment is in power-on state. Implemented a firmware watchdog timer to automatically reset the controller in a stuck situation.

Endnote

During development, an experienced engineering team assesses the product specifications and technical feasibility. If they discover adjustments that can save time, reduce costs, and enhance the product, they collaborate with the client to explain these changes and their benefits, ensuring mutual agreement.

Once development and laboratory testing are completed, the team conducts field testing to verify the specifications before approving the design for mass production. This step is crucial for identifying and rectifying unforeseen issues that could otherwise lead to costly failures.

Ultimately, product development engineering is a challenging, innovative, and rewarding journey for passionate engineers.