Short answer: An electronics product goes through seven stages: (1) concept and feasibility, (2) architecture and schematic, (3) PCB layout and firmware bring-up, (4) prototype build and verification, (5) design for manufacturing and test, (6) pilot series and certification (CE: EMC, safety, radio), and (7) series production with change control. For a typical industrial device the path takes 4–9 months. The stages that decide success are 5 and 6, because that is where a design becomes a product that can be built, tested and certified repeatedly. Comtec Labs runs all seven in one team.
The seven stages
| Stage | Deliverables | Typical duration |
|---|---|---|
| 1. Concept and feasibility | Requirements, block diagram, key component choices, cost and risk estimate | 1–3 weeks |
| 2. Architecture and schematic | Schematic, power budget, interface definitions, firmware architecture, BOM draft | 2–6 weeks |
| 3. Layout and bring-up | PCB layout with DFM review, first firmware (bootloader, drivers), mechanical fit | 3–8 weeks |
| 4. Prototype and verification | Assembled prototypes, functional and environmental tests, issue list, revision | 4–8 weeks per iteration |
| 5. Design for manufacturing and test | Panelisation, test points, test specification, factory test software, coating spec | in parallel with stage 4 |
| 6. Pilot series and certification | Pilot batch on production lines, EMC/safety/radio pre-compliance and certification, documentation | 4–12 weeks |
| 7. Series production | Production against forecast, traceability, engineering change control, obsolescence management | ongoing |
Where projects fail, and the fix
- Requirements that keep moving: freeze the interfaces and the environment specification before layout; change them only through a documented change.
- Prototype built on a bench, not on a line: build even the first prototype on production SMT lines so it is also the process qualification.
- Certification as an afterthought: run EMC pre-compliance on the first prototype; a redesign after formal testing costs a revision and two months.
- No test strategy: write the test specification while designing; test points and connectors cannot be added after layout.
- Component risk ignored: check lifecycle and alternates in stage 2, not when purchasing for the pilot.
How the R&D-driven model shortens the path
When design, firmware, test and production are one team, stages 3 to 6 overlap instead of queueing: the test fixture is designed while the layout is routed, the factory test firmware grows with the application firmware, and the pilot series runs on the same lines that built the prototype. In our experience that removes at least one full prototype iteration from a typical project.
Key facts
- Typical time from idea to series for an industrial device: 4–9 months.
- Each avoided prototype iteration saves 4–8 weeks and one NRE set.
- CE marking for an industrial device usually involves the EMC Directive 2014/30/EU, the Low Voltage Directive 2014/35/EU and, for wireless, the Radio Equipment Directive 2014/53/EU.
- Comtec Labs delivers all seven stages in Vaasa, Finland, with prototypes and series on the same lines.
What you need to start
A one-page description of what the device must do, the environment it lives in, the interfaces it needs, the target unit cost and the expected volumes. From that we produce a stage plan, a development quote and a unit-cost forecast within two weeks.
Frequently asked questions
How long does it take to develop an electronics product?
Typically 4–9 months from concept to series for an industrial device, depending on certification scope and the number of prototype iterations.
What does electronics product development cost?
Development is quoted per stage in engineering hours plus prototype material; production is quoted per unit. A concept study gives you both figures before you commit.
Can you certify the product?
We run pre-compliance testing in-house and manage formal EMC, safety and radio testing with accredited laboratories, and prepare the technical documentation.
Do you also handle mechanics?
We design the electronics to the enclosure and work with mechanical partners for housings; box-build assembly is available.
Ready to reduce PCB surprises?
Comtec Labs offers a full suite of services to streamline your workflow:
PCB design service
PCB prototyping service
PCB component sourcing
PCB component assembly
PCB testing service
PCB repair and modifications
Printed circuit board production
PCB mass production