Prototype development is a critical step in the design and development of any product. It is extremely important that the scope of prototyping is clearly outlined before the start of the process. This process becomes especially complex and crucial when the project's core development is completely driven by hardware designs. Rapid prototyping techniques enable us to mitigate some of these challenges by following an agile approach in the complete design and development phase.
Primary challenges in this phase include sourcing against higher MOQs, low-volume production, and assembly set-up capital. This is achieved by following a modular approach where we try to use existing designs that are available in off-the-shelf fashion and have production capabilities as well.
The goal of rapid prototyping is to quickly test and validate design concepts before committing to full-scale production. This allows for early detection of design flaws and allows for adjustments to be made before the final product is manufactured. It can also be used for proof-of-concept demonstrations, user testing, and market validation. Rapid prototyping can be applied to a wide range of industries, including automotive, aerospace, medical, and consumer products. Rapid prototyping is often misinterpreted as a quick, rough build of the final design. However, rapid prototyping for hardware design can be fruitful only if a strict process is followed during the design and development phase.
Following an established process, in the development phase, ensures the components are sourced with negligible lead time without committing to production volumes. Further, the choice of components drives the complete assembly process which defines the production cost for the initial prototyping. Assembly of hardware needs to be thought through early on to ensure a smooth supply chain and assembly process for e.g., no custom process or machinery is required for soldering small form-factor components such as VQFN, BGA, or 0201 sized components.
For any developing company it is very important to be wary about the different rapid prototyping techniques which can enable the quick realization of hardware concepts. We are in times, where new prototyping approaches are being developed on a regular basis. Being up to date with these techniques will ensure, we have a faster turn-around for the delivery of the individual modules.
Some of the most common electronics rapid prototyping techniques include:
Breadboarding: Though traditional, this is considered the best technique for the initial setup and test. In this technique, electronic components are mounted on a general-purpose prototyping board, known as a breadboard. Connections are made using pre-tinned and soldered wire. This allows for quick make and break of connection and ready alterations in the designs. Once we have an initial working model on a breadboard, it is better to move to a general-purpose PCB-based design.
PCB prototyping: PCB manufacturing has undergone a revolutionary development in the last decade, which has allowed us to get PCB within 24-48 hours with production-level specifications in track width, clearance, and via sizes. Having prototypes in fabricated PCB allows us to have a system close to the final production quality design.
Rapid SMT assembly: Surface-mount technology (SMT) allows for the rapid assembly of electronic components onto a PCB, which can be used to create working prototypes of electronic devices. This decision is often driven by the complexity of the design and the grade of performance.
Microcontroller and single-board computer development: During the early stage of development, it is quite challenging to lock down on the microcontroller or system platform. Building these systems from scratch can pose its own inherent challenges. Using development boards or single-board computer is better to eliminate these problems and switch between systems if any problems are noticed.
It is important to note that these processes are not linear and may involve multiple iterations and adjustments during the development process. Additionally, the process may vary depending on the industry and the complexity of the product. Having a design where we can switch between individual blocks between systems is important to ensure there is no major overhaul in the development process. During the drawing board discussions, it is advisable to scope the complete project and identify the different sections. This is very important and critical to be an integral part of the design process.
Having a modular approach allows us to have blocks of hardware that can be used in multiple design iterations. This also provides a convenient development pathway where it is possible to change just a block in the design without affecting the remaining circuit. In the absence of this approach, there might be a need to change the complete system. This further pushes the development timeline.
For us, delivery of proofs-of-concept at a high pace has been with a clear sight of the target profile of the prototype we plan upon. It is the combination of defining the early scope of requirement, efficient use of rapid prototyping techniques, and a modular design approach that has allowed us to deliver prototypes which can be scaled to production design with reduced iteration cycles.
Do you struggle with hardware rapid-prototyping which is DFM-ready?
Yes. Finding partners for rapid prototyping is a struggle.
No. We have aced rapid prototyping.
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