From Idea to Mass Production: Unlocking the Secrets of Successful Hardware Product Development

The hardware and IoT product development process is a lengthy and costly endeavor, presenting challenges and pitfalls to newcomers and those who underestimate the associated risks and project stages. In this article, we aim to break down the process of product design and engineering development into phases and milestones that are utilized by professional design houses, new product development companies, and engineers.

In summary, the new product development life cycle can be divided into three major phases:

1. Idea, Product Definition, Feasibility, Conceptualization:

This initial phase involves defining the product concept, evaluating its feasibility, and conducting research to gather requirements and understand market demand. Conceptual mock-ups and demonstrators made from materials like paper, clay, or wood are created to foster consumer-centric thinking and aid industrial designers in generating sketches and renders.

It is crucial to distinguish between Proof of Concept (POC) and Minimum Viable Product (MVP) in hardware development, as these terms are often confused. POC functionality is constrained and does not match the final product, whereas an MVP in hardware refers to a prototype that can be showcased or sold to actual customers in order to gather valuable product feedback.

2. Development and Prototyping:

This phase encompasses engineering validation testing (EVT), design validation testing (DVT), and production validation testing (PVT). EVT involves developing work-like prototypes to validate and refine the core functionality of the product. DVT focuses on finalizing the design and ensuring compliance with various standards and certifications. PVT involves testing a small batch of prototypes to stabilize the quality of the manufacturable product before mass production.

a. The purpose of the engineering validation testing (EVT) phase is to integrate prototypes of subsystems that resemble the final product and demonstrate the intended functionality according to the Product Requirements Document (PRD).

• The objective?of the EVT is to combine look-alike and work-like subsystem prototypes made of intended components to meet the functional requirements in the form factor as per your PRD (product requirements Document).?
• EVT prototype quantities: 3-50 units, depending on the design complexity and BOM cost. On average, 5-12 prototypes are required to complete the EVT.
• Technologies: 3D printing, laser cut/milled PCBs, soft tooling (silicon molds), professional hardware development kits (HDK), rapidly cut/milled parts;
• Outputs / Deliverables: fully-functional prototype with key components performing as intended.
• Limitations: Prototypes delivered throughout the EVT phase may look somewhat ugly, raw and have a lack of beautiful cosmetic finish. The EVT prototype can also miss some non-key mechanical features such as handles, curves in enclosure, painting, etc.

Once the EVT phase is completed, the focus shifts towards the industrial design to create the final appearance of the product. Any industrial design work (whether in the form of renders, sketches, or CAD) conducted prior to this stage is not applicable to the actual dimensions, weight, and module arrangements. The late alpha prototypes, which combine both functionality and aesthetics, aim to materialize the true visual representation of the industrial design.

b. The primary goal of the design validation testing (DVT) phase is to establish a fixed design, including dimensions, weight, materials, finish, and moving mechanical parts, while also rationalizing the features of the final product.

The objective?of the DVT is to fix the design (i.e. dimensions, weight, materials, finish, moving mechanical parts) and rationalize the final product’s features.?

• DVT prototype quantities: typically 20-200 units, depending on the design complexity and BOM cost. The prototypes will be used for various reasons: certification lab tests, “beta tests” with early customers/testers.
• Technologies: 3D printed + gel-coated enclosures with the finish “as from the factory”, rapidly cut/milled parts; industrial equipment (e.g. injection moulding) and 1st generation tooling (e.g. “quick moulds”).
• Outputs / Deliverables: a [batch of] functional prototypes ready for mass-production with BOM and a design documentation package. Boxing and Packaging design completed. Estimate mass-production yields?
• Limitations: The DVT prototypes and documentation is nearly final and can be slightly changed further in development. Some mechanical parts and electronic components may not be final due to economic reasons (e.g. it is cheaper to CNC mill some metallic parts instead of using dye casting).

c. Production validation testing (PVT) Prototype Quantities: Typically ranging between 50 and 500, these prototypes serve the purpose of verifying mass-production yields and providing product samples.

• Technologies: Industrial technologies specifically tailored for high-volume production are employed during the PVT phase.
• Outputs / Deliverables: The final product is produced in a limited quantity, utilizing tools designed for mass-production. The electronic layouts and components undergo revision, with the use of PCB stencils for efficient soldering of components. Additionally, the mechanical Design for Manufacturing (DFM) is finalized, and plastic parts are manufactured using second-generation molds.
• Duration: The PVT phase generally spans a duration of 3-6 months.
• Limitations: It is important to note that the design and production of custom tools typically entail a lengthy process

Throughout the development process, it is crucial to achieve specific milestones such as Proof of Concept (POC), Engineering Validation Testing (EVT), Design Validation Testing (DVT), and Production Validation Testing (PVT). These milestones help ensure the project progresses effectively, minimizes risks, and stays within the estimated budget.

It's important to note that each phase involves different types of prototypes, from conceptual mock-ups in the early stages to fully-functional prototypes ready for mass production. The prototypes evolve in terms of functionality, appearance, and manufacturability as the development process advances.

3. Volume Production:

This phase marks the official commencement of mass production (MP) after successfully completing the PVT stage. A production run is initiated, typically starting with a quantity of 1,000-2,000 units, which undergo quality and functionality testing to ensure the product meets expectations. Once in mass production, the focus shifts to sales, customer support, and managing the product's lifecycle.

Alternatively, MP1, which stands for the initial volume run on the manufacturing and assembly lines, represents a significant milestone. At this stage, you have finalized the purchase order (PO) and determined the production quantities in collaboration with the Contract Manufacturer (CM).

MP1 typically involves producing a quantity of 1000-2000 units, subject to rigorous quality and functionality testing. Stringent measures are implemented to ensure both QC (quality control) and QA (quality assurance) are upheld, guaranteeing the desired levels of quality and performance.