When does hardware development make sense?

Hardware development is very complex, time-consuming and expensive. Therefore, it only makes sense to develop something that does not yet exist, is no longer available or for which a large number of units are required. For example: if the supply of spare parts for older industrial systems has been discontinued and certain electronic assemblies have an irreparable defect. In this case, it can make sense to replicate this assembly or to develop new hardware that can completely take over its function.

From the idea to the finished hardware product

To successfully develop something, a few steps must be gone through. We will cover these in the following paragraph. As an example, we will use our self-developed electronic business card.

1. Product conceptualisation

The concept specifies which functions must be fulfilled, what environmental conditions exist and how extensible the hardware must be. With this concept, a cost estimate can be created so that you can calculate the economic viability.

As an example, the concept for the „Mosertronik business card“

It should be possible to display various patterns using 10 LEDs. Power is to be supplied by a 3V CR2016 battery. In sleep mode, the current consumption should be as low as possible at <5µA so that the battery lasts a long time. Furthermore, only a few components should be used so that this circuit can be assembled by our visitors themselves on the open day. Environmental conditions are room temperature (range from 10°C to 30°C). An expansion of the circuit is not planned.

Cost estimate

The estimated costs are to be seen as an example only and would include development, assembly, and programming. Please note that the prices are exclusive of VAT.

Piece	50	100	250
Price per item	15,00 €	13,00 €	12,00 €
Total price	750,00 €	1300,00 €	3000,00 €

2. Development of the circuit diagram

Once the conceptual stage is complete, the actual work can begin. During the development of the circuit diagram, individual sections are simulated and built on a breadboard as a test. Depending on how complex the project is, developing the circuit diagram can take anywhere from days to weeks.

Example circuit diagram of the business card

To help you visualise what a circuit diagram looks like, here is the simple circuit diagram for the electronic business card.

3. PCB layout creation

Once the circuit diagram is finished, the routing can begin. To do this, all the footprints (the component land patterns) are transferred to a new page in the CAD software. These must then be arranged in such a way that no tracks cross. Once the components have been properly arranged, they can be connected with the tracks.

As an example, the finished CAD layout of the business card

On printed circuit boards, a distinction is always made between the top and bottom sides, or in German, top and bottom. Here you can see the visualised bottom side of the finished layout.

4. Evaluation of the prototype

Once the layout is complete, the data is sent to the manufacturer. The manufacturer produces the printed circuit board according to our specifications and sends the finished printed circuit boards to us. Only a small number of pieces are ordered for the prototype. As soon as these arrive, they are assembled and software development begins. Even during software development, tests are carried out to check whether all specifications are met. If this is not the case, you start again at step 2 and incorporate the necessary improvements.

The prototype

Following the population of the components and the completion of the software, the prototype is complete. This has all the functions that the series product will also have. The image shows the prototype still without components.

5. Manufacturing of the evaluated hardware

Following the successful evaluation, there is a finished product. Now mass production of the ordered quantity can begin.

Requests for hardware development

If we have convinced you of our expertise in hardware development, you can reach us at +43 2826 – 88 198 or info@mosertronik.com or via our Contact form Contact for further information.