When you are developing a new electronic product, the excitement of getting your prototype to “work” can be electrifying (sorry). But before you speed ahead into mass production, there’s an essential pit stop you can’t afford to miss and that’s a thorough review and redesign for manufacturing.
At Ignys, we often remind our clients that prototypes are a beginning, not the end. They’re a crucial learning tool, a first draft, and almost always in need of refinement. Here’s why taking the time to redesign before hitting the production line is important.
Prototypes Are Made to Learn, Not to Last
A prototype’s job is to test whether your idea works, but they’re not built for manufacturability, reliability, or efficiency. It might pass basic functionality tests, but under real-world conditions, issues can quickly surface. Perhaps a component overheats, or maybe the layout introduces unexpected noise into your signals. Even things like how parts fit together physically or the way heat dissipates need another look.
Redesigning gives you the chance to tackle these problems while they’re still relatively cheap and easy to fix.
Catching Costly Mistakes Early
Small flaws in a prototype can turn into major production headaches. Imagine discovering after tens of thousand units have been made that the PCB layout causes random resets under certain temperatures… and they’re already in the hands of your customers.
Ouch. That’s a nightmare for your timeline, your budget, and your reputation.
By thoroughly redesigning, re-evaluating, and testing, you’re essentially insurance-proofing your project. The team at Ignys, for example, offers design reviews and testing services specifically to catch these kinds of issues before they snowball.
Design for Manufacture and Assembly (DFMA)
Your initial prototype may have been lovingly soldered by hand, but that’s not how your production units will be made. Mass production requires a design that’s optimised for automated assembly and easy testing.
Redesigning allows you to:
- Minimize the number of parts
- Standardise components – providing lower cost per unit
- Improve the layout for automated production
- Reduce assembly time and cost
Without this step, you risk production delays, increased labour costs, and potential quality control issues down the line.
Regulatory Compliance and Testing
Let’s not forget regulatory standards — CE, FCC, UL (depending on geography) and beyond. Getting your electronics certified often requires specific design considerations. Maybe your prototype passed your in-house functional tests, but is it immune to electromagnetic interference? Is it safe under a fault condition?
Redesigning with compliance in mind saves you from failing certification tests late in the game, which would force expensive rework and retesting.
Customer Experience Matters
The real users of your product will care about things beyond functionality — such as durability, battery life, heat generation, and even aesthetics. Refining your design ensures you’re delivering something that not only works but delights.
For instance, improving energy efficiency might mean selecting different components or reworking the power management circuits. Better thermal management might require tweaking the mechanical design. Each adjustment makes the final product that much stronger in the eyes (and hands) of your customers.
Conclusion: Redesign is an Investment, Not a Delay
It’s tempting to see redesign as a frustrating hurdle between you and your “big launch,” but think of it as an investment in your product’s future success. Every hour spent refining the design saves days, weeks, or even months of troubleshooting after production.
At Ignys, we’re passionate about helping innovators turn good prototypes into great products. If you’re at the exciting prototype stage, let’s have a chat about how we can help you redesign smartly, efficiently, and successfully.
Contact us today – we’re never “salesy” or prescriptive and we’re always happy to talk shop.