One of the natal and most crucial stages of electronic devices’ production is the design stage. It encompasses the creative, manual, and technical facets incorporated in an electronic device. The design stage allows manufacturers and developers to convert a textual system definition into a detailed and functional prototype before mass production. Almost all the functional requirements of an electronic device are addressed at the design stage itself.
Considering the BOM and the DFM are crucial at this stage to maintain or improve quality,
while keeping a check on the cost and expected features and performance.
Fundamentals of the Design Process
- Prior to investing in materials required for manufacturing, it is essential to establish a
list of requirements. This helps the manufacturer understand the features required in
the product. Similarly, it is essential to conduct a thorough market research to identify
market gaps and consumer requirements to develop products that can address the
consumer needs. A successful product is one that fulfills what the market of similar
products lack. - Subsequently, after the conceptualization is complete, the focus shifts to creating a
design proposal and project plan. This defines the projected expenses involved in the
manufacturing process, an approximate timeline, along with other design and
manufacturing process segments. - A final electronic device comprises of several small components like multiple
microcontrollers, displays, sensors, and memory to name a few. The advent in
technology has allowed us to leverage the usage of advanced software like Electronic
Computer-aided design (ECAD) or Electronic Design Automation (EDA) tools to
create the schematic diagram. These help in reducing the scope of error and act as
catalysts to the design process. - Eventually, the detailed schematic design proves beneficial for the next step where the
schematic is transformed into a PCB layout.
Growing Trends in the Design Process
- The advancement in nanotechnology and microfabrication techniques have evolved
the design process to allow for further miniaturization with increased integration on
chips. Design engineers can now add more features than before on a single chip along
with reducing its size. - Present day electronic designs are trying to incorporate the usage of renewable energy
as the industry shifts from fossil fuels. This change has forced designers to maneuver
the design of electronic devices along with incorporating advanced features like IoT
efficiency. - The growing demand for sustainable devices has equally affected the design process
which now needs to include features to reduce greenhouse gas emissions as well as
reduce energy consumption. This has influenced electric designers to modify power
converters and motor drives to reduce energy loss and increase efficiency. - The contemporary times also require the integration of automation and robotics for
both industrial and consumer electronic devices. The design process hence, has to assimilate these requirements to maintain the longevity of the electronic device to
allow its easy adoption of advanced technology. The same goes for integration with
artificial intelligence, a growing rage and one that is bound to prove monumental in
the simplification of the process and usage of electronic devices. - The major challenge in the design process is not the integration of such features but
their human-friendly integration. Any feature in a device can fail to fulfil its purpose
if it is not user-friendly, hence, the task falls on design engineers to make their access
easy and durable. - Apart from the features and structural innovation, the design process in upcoming
electronic devices has also undergone a change in the materials used. Newer, flexible
devices have changed the dynamics from rigid circuit boards to flexible substrates and
conductive polymers. Electronic designers are now compelled to adhere to even
mechanical flexibility in their electronic layouts.
Simplifying the Process for Complex Designs
As the need for miniaturisation and integration grows, the complexity of the design follows
suit, however, advancements in software and applications have simplified the process,
allowing designers to experiment with more creative ideas without compromising on the
timeline and costs.
While ECAD is one such innovation which has been adopted extensively now, some other
EDA tools are:-
- SPICE: This is a simulation tool used to analyse and predict the circuit's behaviour
under different conditions before building a physical prototype. It helps, identify and
fix potential issues in advance. - OptSim: This software tool allows designers to evaluate and optimize the
performance of optical links within a sensor design, predicting how light will behave
through components like lenses, fibres, and detectors.
Conclusion
Designing for electronic devices is a dynamic process and requires engineers to stay up-to-
date with the industry and market trends. As automation, robotics, and artificial intelligence garner a strong hold among electronics, their integration for the design process is inevitable. The design process is that vital and non-linear stage in manufacturing which often continues even post testing for refinement and then for documentation and certification.
