How Does the Electronic Design Process Work From Idea to Prototype?

Electronic design is a process that requires an interdisciplinary approach and involvement of various engineering fields. It is based on a synergy of engineering knowledge, creativity, and attention to detail. When combined with experience and excellent collaboration among specialists, the chances of achieving a well-crafted product significantly increase. At EMAG-SERWIS, thanks to its specialized team of experts, each stage from concept to prototype is efficiently executed. In this article, we explore each phase of this complex process.

Stage 1: Defining Requirements and Product Specification

This initial stage demands high involvement from both mechanical and electronic engineers. They are responsible for defining the product’s goals in detail, considering industry specifics and client expectations.

Mechanical engineers handle:

  • Creating construction models;
  • Selecting materials and analyzing durability;
  • Considering ergonomics and device functionality.

Electronic engineers contribute by:

  • Defining technical requirements for electronic systems;
  • Optimizing logic and analog circuits;
  • Specifying interfaces and modules.

Close cooperation between the mechanical and electronics departments ensures a coherent specification that meets both technical and legal requirements.

Defining the product goal involves answering key questions early in the process:

  • What problems does the product solve?
  • Who is the target user?
  • What are the product’s key features?
  • What are the budget and time constraints?

Technical specification includes:

  • Block diagram of the device;
  • Description of individual modules;
  • Required interfaces list;
  • Power supply requirements;
  • Environmental requirements (temperature, humidity, vibrations);
  • Applicable standards and regulations.

Feasibility study supports decision-making by objectively evaluating:

  • Component availability;
  • Regulatory compliance;
  • Production cost estimates;
  • Technical risk assessment.

Stage 2: Schematic Design

At this stage, electronic engineers and programmers play a vital role. They design the electronic circuits and simulate the performance of individual system elements.

  • Engineers design schematics, select components, and run simulations;
  • Programmers support development by creating embedded software and implementing test algorithms.

At EMAG-SERWIS, experts use advanced CAD tools such as Altium Designer, while programmers proficiently work with C/C++ and FPGA technologies.

Component selection criteria:

  • Technical parameters;
  • Availability and pricing;
  • Manufacturer reliability;
  • Environmental compliance.

Schematic creation uses professional tools and design rules:

  • CAD software (e.g., Altium Designer);
  • Clarity and readability;
  • Compliance with design standards;
  • Noise minimization;
  • ESD protection.

Simulations verify whether the project meets expectations and mitigate implementation risks:

  • Tools: SPICE, TINA;
  • Goals: validate functionality, optimize parameters, and perform sensitivity analysis.

Interested in Collaboration?

Feel free to reach out.

request a FREE CONSULTATION
(phone or video call)

Stage 3: PCB Design (Printed Circuit Board)

PCB design demands exceptional precision and experience. Here, PCB designers and quality controllers ensure the design is ready before prototyping.

PCB designers:

  • Create precise PCB layouts using Altium Designer;
  • Optimize component placement to minimize EMC interference;
  • Perform DFM/DFA analysis for manufacturability and assembly.

EMAG-SERWIS engineers validate the PCB design for technical compliance and conduct audits per IPC-A-610 and IPC-7711/7721 standards.

Design criteria:

  • Number of layers;
  • Substrate material;
  • Trace thickness;
  • Drilling technology;
  • Surface finish.

Component placement rules:

  • Short trace lengths;
  • Separation of analog and digital signals;
  • Proper cooling;
  • EMC compliance.

Routing rules:

  • Avoid sharp angles;
  • Impedance control;
  • Crosstalk minimization;
  • Proper grounding.

Gerber file generation:

  • Industry-standard format for PCB production;
  • Includes data for all layers, holes, and markings.

Design verification:

  • Consistency with schematic;
  • DFM/DFA analysis.

Stage 4: Prototyping

This is where the expertise of assembly technicians, mechanics, electronics engineers, and quality controllers converge to build the first physical model.

  • Assemblers mount components using SMT or THT technologies on advanced lines;
  • Mechanical engineers prepare housings and structural parts;
  • Controllers test functionality and quality from electrical to environmental testing.

At EMAG-SERWIS, prototypes are produced using automatic assembly lines and skilled manual labor. Controllers conduct thorough functional testing to eliminate issues before mass production.

PCB supplier selection criteria:

  • Cost;
  • Lead time;
  • Quality;
  • Special technology availability.

Component assembly technologies:

  • SMT (Surface Mount Technology);
  • THT (Through-Hole Technology).

Assembly quality control (e.g., AOI PARMI Xceed L):

  • Visual inspection;
  • Electrical testing.

Prototype testing involves:

  • Functional tests;
  • Performance tests;
  • Environmental tests;
  • Safety tests.

Stage 5: Refinement and Optimization

After testing the prototype, necessary corrections or improvements are identified. Coordination among process, electronics, mechanical engineers, and quality controllers is key.

  • Process engineers analyze test results and suggest improvements;
  • Mechanics and electronics engineers make design adjustments;
  • Controllers re-test to validate modifications.

EMAG-SERWIS offers full support at this optimization stage through department synergy. An iterative approach ensures each prototype version improves in quality.

Test result analysis helps identify:

  • Specification mismatches;
  • Design errors;
  • Component issues.

Adjustments involve:

  • Changing component values;
  • Improving trace routing;
  • Adding EMC-reducing elements.

Design optimization goals:

  • Reduce production costs;
  • Improve performance;
  • Increase reliability.

Validation of changes:

  • Re-run prototype tests;
  • Analyze new results.

Stage 6: Documentation and Preparation for Mass Production

The final stage involves creating the documentation and procedures required for full-scale production.

Production documentation includes:

  • Schematic diagram;
  • PCB design;
  • BOM (Bill of Materials);
  • Assembly instructions;
  • Testing instructions.

Quality control procedures:

  • Incoming component inspection;
  • In-process checks;
  • Final product inspection.

Summary

Electronic design at EMAG-SERWIS is the result of interdisciplinary collaboration combining expertise in various engineering fields. Electronic engineers, mechanical engineers, designers, programmers, assemblers, controllers, and process engineers work together from concept to prototype. Key success factors include precise requirements definition, careful design, thorough testing, and continuous improvement.

EMAG-SERWIS provides comprehensive electronic design services, from concept to finished prototype. Each stage, from requirement analysis to final testing, is executed with precision to ensure the highest quality. Our experienced team uses cutting-edge CAD/CAM tools and simulation software to develop innovative and reliable solutions. Close collaboration with the production team enables project optimization for cost and efficiency, ensuring a smooth transition to serial production.

Together with our Partners, we drive technological and market success.

Bibliography:

Share this article with your colleagues.
Home Phone Custom