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electronics design

Collaboration that delivers

reliable, robust hardware advanced electronic solutions precision engineered circuitry

Electronics Design is a core capability that underpins our specialty in electronics product development. We work with clients to design and develop Printed Circuit Boards (PCBs), cables, batteries, sensors, antennas, and all other hardware inside products which enable electronic functionality. When navigating this development work, we always put forward the most suitable solution for our clients’ needs – either integrating existing components available off-the-shelf, or designing custom solutions tailored to the needs of the product and users.

What is electronics design in product development?

Any product with electronic features – no matter how basic or complex – requires some level of electronic hardware design. Often, this involves custom PCB design, cable design, and other custom designs. Electronics design is about creating a hardware platform that hosts an embedded system and provides connectivity between sensors, actuators, and user interfaces. 

Translate product requirements into a hardware architecture 

  • Selecting critical/core components early in the process to prioritise their importance for the hardware’s foundation.
  • Designing all necessary interfaces and interconnections to ensure proper communication and function among components.
  • Creating a hardware architecture where each design element aims to address a specific product requirement.
  • Consider also the power system – many modern products require several different voltage rails, low power modes, and reliable power delivery. 
  • Drafting schematics to include all necessary component symbols, interconnections, and well-organised sheet planning.
  • Designing a Printed Circuit Board (PCB) for each schematic project, ensuring it has all required components and is well designed.
  • Collaborating with suppliers to source or customise external electronic parts, such as cables, sensors, and antennas.
  • Creating a comprehensive Bill of Materials (BOM) that lists every component used throughout the entire system – not just on the PCB.
  • Converting all design (CAD) files into manufacturing (CAM) files, preparing them specifically for the production process.
  • Submitting detailed Requests for Quotation (RFQs) to various manufacturers and suppliers to gather bids for production.
  • Negotiating favourable pricing and realistic lead times with chosen vendors, then managing the ongoing supply of all components needed for the prototypes.
  • Finally, either building or receive the completed prototypes, ensuring they meet the design specifications.
  • Create a comprehensive test plan well in advance of any physical testing to guide the process.
  • Source any additional equipment, materials, and tools necessary to effectively conduct the planned testing.
  • Execute the defined testing protocols rigorously, focusing on testing the hardware in isolation wherever possible.
  • Once the hardware is proven and no issues are present, move onto integration testing in collaboration with the embedded software team.

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Success factors for electronics design  

There are several well-known best practices in electronics design that inexperienced designers often overlook. Here are some we think are worth highlighting, and that we always consider in the forefront of our day-to-day development.

  • In most designs, the majority of components (around 90%) are not critical and can be substituted if needed without significant impact.
  • Critical components, such as processors, specialised sensors, and unique modules that are vital to the product’s core functionality are typically not easily substituted – if they can’t be purchased, the entire product could require redevelopment.
  • Work closely with manufacturers and distributors to profile the long term availability of critical components and use this to inform your design decisions.
  • Consider multi-sourcing critical components where possible to reduce dependence on a single supplier and enhance supply chain resilience.
  • Design for manufacture (DFM) techniques and best practices ensure the final design does not just function as intended, but is easy to produce.
  • This involves many key areas of focus, such as Design for Test (DFT), Design for Assembly (DFA), and Design for Fabrication (DFF).
  • Some examples include ensuring the PCB design has test points exposed for mating with a test fixture in production (DFT), all components are placed on a single-side (DFA), and using standard PCB stackups available from all common fabricators (DFF).
  • DFM techniques are not always possible to implement into the day, especially for dense, small, and complex designs – but wherever possible, these should be considered and put forward as a preference, especially for products which will be produced in high volume.
  • Using the absolute latest technologies can provide competitive advantage, but comes with risks – like poor support or hidden bugs.  
  • Whatever technology is chosen, always choose a reputable vendor with a track record of great support and reliable supply. 
  • It’s best to go with the solution your engineers are most comfortable with, ensuring smoother development.
  • Balance the desire for innovation with the business imperative of reliability.
  • Embrace an iterative design process that allows for continuous refinement based on real-world test results, to optimise performance and reliability.
  • Use simulation, calculation and estimation on system elements, like power consumption, complexity and cost, to understand and mitigate risk. 
  • Real-world testing usually reveals unexpected factors, so always test and verify a requirement is met.  
  • Never rely on only simulations or only real-world testing – a dual-pronged approach is always best.

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Why product companies should care Electronics Design

Electronics hardware transforms ordinary mechanical products into smart, value added devices and can provide a strong barrier to entry for competitors with software-only products. Companies should pay close attention to minimise upfront investment and overall cost of ownership.

  • There are certain elements in the electronics design process which means it is almost always on the critical path of your product development project – such as initial component research, prototype lead time, and production setup.
  • By nature, most of the steps in electronics design are waterfall. The PCB design cannot generally start, until the schematic capture is complete. Prototypes cannot be ordered, until the PCB design is complete. However, with some creative tactics, this can be overcome.
  • It’s worth giving hardware the attention and valued focus it deserves to optimise your time to market. 
  • A product should be designed to make is as easily manufactured as possible, to minimise production costs and increase yield. 
  • Junior and mid-level engineers usually lack DFM knowledge and require guidance on key design choices, from experienced designers. 
  • Ensuring DFM principles are adhered to early in the development cycle, through formalised design reviews, avoids cost surprises in manufacturing and prevents redesigns. 
  • Always balance the needs and wants of the product with the commercial reality of what it will ultimately cost to produce.
  • All products with electronics need to meet the regulations of the markets they are sold in, and businesses face penalties if non-compliant.
  • The most common compliance requirement in product development generally refers to product labelling, such as Australia’s Regulatory Compliance Mark (RCM), European Conformity (CE), and the USA’s Federal Communications Commission (FCC) certifications.
  • It’s a common misconception that only some products (medical, cellular, defence and other specific industries) must meet regulatory compliance. The only difference is these types of product have a much higher and more rigorous set of requirements. 
  • There is a complex web of overlapping regulations to navigate, requiring experience to avoid pitfalls. 

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How collaboration delivers your trusted electronics foundation

Because hardware is on the critical path for product development, optimising the electronics design process demands strong and effective collaboration between the key project stakeholders. Here are some important collaboration principles: 

  • Your product will be produced and assembled by one or more contract manufacturers, including an electronics manufacturer.
  • The manufacturer has the most knowledge of how best to optimise the manufacturability of a product for their equipment and processes.  
  • Manufacturers also have the best visibility of component life cycles and stock availability, minimising the likelihood of production delays. 
  • Involving the manufacturer early can positively influence design choices and minimise production risks – as early as possible.
  • The ability to have regular face-to-face meetings minimises miscommunication, helps streamline processes, and ensures easier issue resolution. 
  • It’s faster to iterate versions of your prototypes, with shorter lead times on things like shipping and travel to meetings.
  • Local manufacturing provides a lower vulnerability to currency fluctuations and more stable estimation of costs.
  • Using already approved suppliers from your network or a referral provides a higher assurance of intellectual property protection.
  • There is always more than one solution to a given problem, and no individual alone knows the best technology choice. 
  • Available components and solutions continue to rapidly evolve. New standards, chips, modules are released every single month.
  • A team with experience vs a team without experience can lead to huge differences in timeline just by choosing the right components.
  • Selecting the right option is about collaborating to develop a roadmap that serves both current and future needs, business and technical needs, and balances performance/cost considerations. 
  • Scaling a product as a business grows means evolving the design for more efficient higher-volume manufacture. 
  • Reliability and end user satisfaction becomes even more important as minor issues become magnified with scale. 
  • Relationships with suppliers, manufacturing and distribution partners needs to be more of an ongoing partnership, to drive efficiency gains. 
  • By using contract suppliers for product design, development, and manufacturing, you can scale the resources required as you need.

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Frequently Asked Questions

on electronics design for products

What testing do I need to do for regulatory testing of my electronic design? 

Regulatory testing usually includes electromagnetic compatibility (EMC) and electrical safety checks at a minimum, with additional standards depending on region (e.g. US vs Australia), application (e.g. consumer vs automotive vs medical), and components in the design (e.g. a product with Wi-Fi will have additional tests required). Testing ensures your product is legally compliant and safe for market use.

Use custom components when you need unique functionality, optimisation, or IP protection, while off-the-shelf parts are best for cost, speed, and availability. Custom components also have the advantage of form and size – you can design them around the form you want your product to have. On the other hand, if using off-the-shelf parts, you need to design your product form around the components themselves, which can be challenging.

PCB costs increase with higher layer counts, finer traces, tight tolerances, and quick turnaround requirements. Other advanced features can include controlled impedance, flex-rigid features, and specialised materials (e.g. specialised RF, high-voltage, or high-temperature fibreglass).

Components becoming obsolete (also known as “end of life”) is a challenge every product company must face. If a component becomes obsolete, you may need to redesign with an alternative part, qualify replacements, or engage in a last-time buy to maintain production.

Development costs vary widely based on complexity, compliance needs, and production scale, typically ranging from a few thousand to hundreds of thousands of dollars. 

Electronics design timelines can range from 1-2 months for simple projects to several years for complex products (medical or defence industries).

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Our Capabilities

Learn more about our other capabilities that support our product development services

Project
Management

Systems
Engineering 

Electronics
Design

Embedded
Systems 

Software
Development

Product
Manufacturing