Tag: new product development

A common pattern we see: a startup hires several low-hourly-rate freelance hardware engineers (mechanical, electronics, and/or firmware engineers) from different countries like Jordan, Pakistan, Vietnam, etc. Work seems to progress…until it doesn’t. Typical failure modes include:

• Designs that can’t be manufactured, so large chunks must be redone.
• Partial hand-offs where someone claims “the job is done, it is ready for a factory,” but it is only 30% done.
• Poor cross-discipline collaboration that turns the project into a mess.

The fix is not “work harder,” it’s “set the right safeguards” to prevent this from happening in the first place. Here are the 4 safeguards that we suggest…

1. Qualify the freelance hardware engineer’s prior experience in designing manufacturable products

Don’t select freelance hardware engineers purely on the hourly rate. Ask candidates to show prior Design For Manufacturing/Design For Assembly examples, for example, such as the improvements shown here: DFM for plastic injection molding or here: DFM for PCBA. Let them explain what they changed to hit yield, cost, and cycle-time targets. If they can’t describe how the manufacturing process will work in detail, that might be a red flag.

If you pick the lowest-cost designers, they might do work that later has to be scrapped entirely and restarted from scratch. For example, we have seen a number of enclosures that can be 3D printed but can’t be mass-produced for a reasonable cost.

For deeper context, see Agilian’s practical DFM tips and comparisons.

2. Ensure you get the deliverables a manufacturer will need

Freelancers often “finish” without producing factory-ready outputs. The problem is, many manufacturers just want to produce and don’t have the will or the capability to do a nice job fine-tuning your product.

Up front, list exactly what you expect to receive: an engineering BOM (ideally with second-sourced options for critical components), documented evidence about pre-certifications of critical-to-compliance components, 3D drawings, tolerance-controlled 2D drawings with the usual mentions (CTQ points, CMF details), functional test reports, function test jigs, the QC checklist, and so on. Use a stage-gate mindset and review deliverables before paying milestones.

Sofeast’s NPI resources and deliverables review service helps you confirm that you receive what the manufacturer will need.

You may also find this video, Typical Deliverables You Should Expect From Product Designers During Product Development, helpful:

Typical deliverables you’ll want

Mechanical Design

• 3D CAD files: For enclosure, housing, and mechanical components.
  • Typical format: .STEP
• 2D drawings: For manufacturing and assembly.
  • Typical format: .PDF

PCB Design (Electronic Hardware)

• Schematic files
  • Native CAD files (e.g., .SCHDOC for Altium, .DSN for OrCAD) + .PDF
• PCB layout files
  • Formats: Native CAD files (e.g., .PCBDOC, .BRD) + .PDF
• Gerber files: For PCB fabrication.
  • Typical format: .GBR
• Bill of Materials: List of electronic components.
  • Format: .XLSX
• Pick and Place files: For automated assembly.
  • Formats: .CSV, .TXT

Firmware / Software

• Source code: For microcontroller or embedded system.
  • Typical format: .C
• Compiled binaries: For flashing onto the device.
  • Typical format: .HEX
• Documentation: API references, setup guides.
  • Typical format: .DOCX or written in markdown in Github

Packaging Design

• Artwork files: For labels, box design, inserts.
  • Typical formats: .AI (Adobe Illustrator), .PSD, .PDF
• Die-line files: For packaging structure.
  • Typical formats: .PDF, .DXF, .AI

3. Ensure you have access to native files and IP

Make sure your contract states you will get all native design files (mechanical drawings in .step format, PCB schematic + Gerber files, firmware source code & documentation if needed, and so on) and that they’re handed over at each milestone for review, not just at the end.

Avoid situations where R&D is done “in-house” by a party that won’t release files; these could then be used to produce your products without permission or, more commonly, at that party’s selected factory only and at the price they decide. Pair that with the right IP protections and, if needed, custody for critical tooling/data.

Go deeper into IP protection by reading IP Protection in China when Developing Your New Product [Importer’s Guide].

4. If the product is not simple & straightforward, appoint a tech lead

From the start of the project, you may hear the electronic designer fight with the mechanical engineer over the space allotted to the PCB. That’s just an example. An experienced tech lead can make informed decisions and allow you to move forward with confidence.

The tech lead can also review the design work and point out issues or risks. That’s priceless. Bear in mind that design work is often completely restarted from scratch because of seemingly small oversights. Picking the wrong microcontroller chip for a given application may result in wasting 50,000 USD and 3 months of work.

In addition, electro-mechanical products need one accountable integrator (yours or external) who will integrate all elements of the design. To simplify, the firmware must work well with the electronics parts and within the mechanical elements. You want to prevent the “it works on my bench” discussions among the engineers, which usually lead to a dead-end.

That integration work can be done by the manufacturer themselves, if they have an R&D team in-house that can handle this.

Bonus: Final checks before engaging factories

Do a quick review: are designs mature, risks mapped, tests planned, and pilot run criteria clear? If not, keep developing before you approach manufacturers; this shortens time-to-stable-mass-production and avoids expensive backtracking.