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On this page (14 sections)
Proof of concept
Demonstrate the core idea works, often with development boards. Focus on feasibility, not appearance.
A successful proof of concept gives confidence to invest in the next stage.
Engineering prototype
Design a custom PCB close to the final product. Test performance, power and interfaces.
Testing at this stage reveals design issues while they are still inexpensive to fix.
Pre-production
Use final components, enclosures and processes. Validate manufacturability and prepare for certification.
Pre-production builds should match the final product as closely as possible.
Pilot run
Build a small batch to prove production processes and test fixtures, and to supply early customers.
Pilot results show whether processes are ready for volume production.
Volume production
Scale with stable processes, scheduled sourcing and consistent quality checks.
Ongoing monitoring of yield and feedback keeps quality high as volumes grow.
Certification
Most products need safety and EMC testing before sale. Plan certification after pre-production so the design tested is the design you will build.
Certification labs often have waiting lists, so book testing early.
Typical timelines
A simple product may move from concept to pilot in a few months. More complex or regulated products take longer. Component lead times and certification schedules are often the deciding factors.
Building some contingency into your plan helps absorb unexpected delays.
Design freeze
Before production, freeze the design: no further changes without formal review. A frozen design allows component purchasing, test fixture building and certification to proceed with confidence.
A disciplined freeze protects schedules and reduces the risk of errors.
Test fixtures
Production testing needs fixtures and procedures. Develop them alongside pre-production prototypes so they are ready for the pilot run.
Ready fixtures prevent production delays at the pilot stage.
Supply chain readiness
Confirm lead times for every component and place orders early for long-lead items. Identify alternates for single-source parts.
Early ordering protects your launch date from component shortages.
Choosing a partner for the whole journey
Working with one partner from prototype to production avoids repeated learning and keeps knowledge in one place.
A single partner provides continuity and accountability at every stage.
Common delays and how to avoid them
Late design changes, long-lead components, failed certification tests and missing test fixtures are the most common causes of delay. Plan for them early.
Proactive planning is the best way to keep a product launch on schedule.
Production ramp-up
Start production with a moderate batch, review yield and feedback, then increase volumes. A gradual ramp reduces risk.
Lessons from early batches improve efficiency and quality in later ones.
How we help
We support every stage, from first prototype to volume production, with one team and one set of documentation.
Contact us to discuss where your product is today and how we can help it reach production.