Prototyping in Custom Android Development: Turning Concepts into Reality

Bringing a custom Android product to life is a journey filled with innovation, iteration, and discovery. At its core lies the process of prototyping—the creation of tangible, testable versions of your concept. Each prototype serves a distinct purpose, helping refine the product step by step until it’s ready for the hands of users.

In the world of custom Android development, prototyping takes many forms. It could be as simple as an app prototype created in design tools like Figma to test UI and UX, or as complex as a physical prototype, such as a working sample or a trial production unit. No matter the stage, the goal remains the same: bring ideas to reality for testing and improvement. Here’s how the magic unfolds.

App Prototyping Matters in Custom Android Development

Custom Android products almost always run unique software, meaning the development of hardware and apps must proceed hand-in-hand. For app developers, the process often starts with a UI/UX prototype—a digital mockup designed to test the user experience and interface flow. Once these designs are approved, programmers dive into coding.  This is not something Hatch works on, but it’s relevant to the overall product development.

But here’s the challenge: the custom hardware the app is destined for often doesn’t exist yet! How can software developers ensure their apps are optimized for hardware that’s still in development?

The Parallel Sample: Jumpstarting App Development

We solve this challenge with a parallel sample. This is a functional sample of an existing tablet or phone that uses the same core architecture as the final product. By providing a parallel sample at the project kickoff, we give app programmers a platform to start development immediately, rather than waiting months for the first working samples.

An early start is crucial because software development often takes the longest time. With the parallel sample, app developers can test compatibility and functionality from day one, setting the stage for seamless integration with the custom hardware.

The First Working Sample: Bringing It All Together

It takes about 2-4 months to finish the initial development engineering.  At that point it’s time for the first working sample. This prototype represents the initial physical manifestation of a custom Android device.

• What it includes:
  A 3D-printed case, electronics from a small PCBA batch (usually fewer than 10 pieces), and peripheral components like the screen, battery, and camera.
  
• How it’s used:
  About five units are typically produced. Some go to the customer, while others stay with Hatch for intensive testing. Over 1-2 weeks, this prototype is put through its paces to identify obvious issues—casing design, core electronic functions, firmware stability, and overall user experience.

This phase is all about ironing out big wrinkles and ensuring the basic foundation is solid before scaling up.

Trial Production: A Glimpse of the Final Product

Once the working sample is approved, it’s time to take a bigger leap: trial production. Here, we shift from small-scale prototypes to a limited run of 50-200 units, produced using the same mass production tooling and processes as the final product.

• Purpose of trial production:
  These units are the closest thing to the final product, designed for broader testing. By distributing them to end users, we can get feedback about hidden issues that might only appear in real-world conditions or over time. This stage also provides invaluable insights into hardware durability, software performance, and usability.

Why it matters:
No amount of internal testing can replace the feedback gained from actual users. Trial production bridges the gap between controlled environments and the unpredictability of real-world usage.

Prototyping with Purpose: Faster, Better Results

Each stage of prototyping plays a unique role in the custom Android development process. By understanding and embracing these stages—parallel samples, working samples, and trial production—you can achieve faster timelines and superior results.

Hatch believes in empowering customers with the tools and strategies to bring their vision to life. Whether it’s jumpstarting app development with a parallel sample or refining the final product with trial production units, every step is designed to ensure your custom Android product exceeds expectations.

Reach out if you have a solid team, great business, and long term vision for your custom Android product.  We’re here to help.

Creating a custom Android product requires going through a series of smaller processes that, in succession, become the whole product development process.  First, we figure out if the client knows what they want and then ask ‘why’.  Second, we research the client’s use case.  This step is ongoing, both for Hatch and our customer, this way the product continuously gets better.  Hatch then validates the client’s initial product details, based on a better understanding of the use case.  This is an interactive process that takes place over email or phone calls, with written call recaps.

Once the detailed product architecture has been confirmed, based on an in depth understanding of the use case, Hatch proceeds with product engineering. This mainly includes designing the PCBA, mechanical design (internals of the case), and firmware.

Keeping this theoretical process in mind, below highlights a real communication example from a current project.  Witnessing an actual conversation will clarify the concept.  Plus you can envision how it would work with your project.  To understand exactly what this process entails, let’s look at a recent email exchange with an actual customer.

This customer has been working with Hatch since 2018.  They originally asked for our help to get through a complicated and challenging situation with another supplier.  Once that was resolved, they asked Hatch to redevelop their product with quality improvements.  Over the years they’ve grown their business and we’ve maintained a positive working relationship.  Now they’re ready to get started on their second generation product.

Many companies consider using custom Android hardware to get a steady long-term supply of their optimized hardware, rather than using a generic retail device that gets updated every 6-12 months.  Sticking with the same hardware doesn’t last forever though.  After 5-6 years, enough time and updates have gone by to justify an update.  The development process is similar to the first time, but the customer’s understanding of user experience is even better.

The customer pointed out a few things that they’d like to change in the next generation product.  One of the changes they want to make involves the SD card slot.  That component is exposed to enough water and dust that it must be cleaned after a few years to continue working smoothly.  The ideas that Hatch presented were dismissed by the client based on their acute knowledge of the product’s operational environment and users.  This conversation shows how the client presents product needs, Hatch comes back with ideas, and decisions are made.

After receiving new spec requirement from the client, Hatch responded with the following questions:

Reviewed the specs.  Here are some questions.

1. Does the new version use the same case design?  If not, do you have a new case design in mind?  We may be able to make the current mold thicker, like you requested, which is a lower cost option than having to make a new one.

2. It looks like there will be 2 sets of specs (Model A and B).  I’m thinking we use the same PCBA, but Model A doesn’t include the WiFi chip and uses 32GB memory, while Model B has WiFi and 64GB of flash.  Any other differences?

3. You mention using a heavy duty USB port.  What do you think makes the USB ports ‘heavy duty’?  What experiences inspire this comment?

Here’s the client’s response as well as Hatch’s reply to the client:

1. Same design, yes. Thicker and stronger definitely!  I would really like to strengthen the trim bezel around the screen.

(Hatch) In this case I’d like to see if we can modify the tooling of your current case rather than making a new mold as this will save you thousands of dollars.  Modifications based on the changes you’ve outlined: thicker plastic, USB-C, and something to accommodate the suggestion I’ll make below regarding SD card ports.

2. You hit it spot on.  We also need to change the chipset to a more modern one that can handle a newer Android OS.

3. I would like a real USB-C.  We have had customers use the wrong chargers and cook the mainboards and, in real bad situations, cook the batteries. I feel with USB-C and a supporting chipset, we can utilize fast chargers and higher current. Also, USB-C would be a little more modern.

(Hatch) I know the current CPU only supports USB 2.0.  We’ll make ‘USB 3.0 chipset’ and USB-C port par of the new requirements.

Since last fall we have seen an outbreak of SD Ports not working. A solution seems to be cleaning the ports in the service department.  After spending months trying to figure out the problem, I learned the contacts are slowly becoming corroded, in particular the upper SD Port.  These SD ports are probably the most used SD ports in the world, next to professional photographers. Every day customers are using these and they may be inserting sd cards 10 times a day 4 days a week; which means heavy heavy use.  Is there any way to get a heavy duty sd port? Gold contacts? Better builds?

(Hatch) We’ll explore more durable SD card port options.  I’m impressed that you’re not seeing the SD card component breaking off the board based on the heavy usage and rugged clientele.  We’ll note to continue with the same mechanical design in the new versions.

Having that SD card port constantly open in outdoor environments and in different weather conditions exposes the slot to dust and moisture.  With that in mind, what do you think about these ideas:

1. Adding a silicon (soft rubber) plug to the SD card port opening.  It can be attached to the case so it won’t get lost (unless someone breaks it off).  We can attach it in a way that makes it more difficult to remove unintentionally, if you think that’s useful.  A bike light of mine uses this concept to cover the USB charging port and I accidentally pulled it off.  Now, I can’t get it to reconnect.  I can send a photo if you want.

2. A flap, like the one that covers a letterbox, that is closed by default using a spring mechanism, but is flexible to get pushed back when someone inserts the SD card.  That way the hole stays protected and the user doesn’t deal with a plug.  We just need to make sure this is designed to withstand abuse.

The above 2 ideas are ways to achieve the same end result.  If you’re interested in either we can check the mechanical viability of making modifications to the original mold.

And, finally, we established a clear direction with this response from the client:

I like your thought on the port covers for the new models but I will have to say no, it would be more troublesome and they would certainly break off. (just like on your bike)

The ports are getting the moisture from the cards themselves. Being transferred from every card.  Like I said it took me months to get this completely figured out.  Hundreds of times the cards are being transferred in and out of the device, bringing in moisture. (I traced this by having customers send me their sd cards that seemed problematic).

Also keep in mind, at a minimum, 95% of the time these sd ports are occupied with cards.

You made a very good point about the ports not being torn off the board.  I can tell you we have not had one single problem with that from any of the lots; Not once! Good job on your team’s part!

This exchange highlights the initial part of the product development process.  It starts with understanding the use case and environment.  We use creativity, experience, and communication to define the ideal approach.  Now it’s time to get to work!

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Economics and Rational of Custom Android Hardware

To measure the economic implications of making a custom Android tablet (or custom Android phone), first look at the company’s history with Android hardware. Does the company already purchase Android devices? If yes, which kind of Android device? For example, tier 1 brand Android devices, no-name brand devices, manufacturer-direct devices, or a custom Android device. If the company is just getting started, they should begin by using a basic retail device before making a custom one.

Starting from Scratch

With many tech projects, both software and hardware, product designers have a hard time knowing exactly how end users will react to the features and interactive designs they create. Trying to design an ‘end product’ from the concept stage is nearly impossible to do perfectly. The ways customers use a product rarely matches expectation. For this reason companies go through multiple rounds of beta testing before releasing a product to the general public. Each round of testing generates feedback that improves the product’s user experience.

Product improvement in the early phases is an ongoing process of quick iterations. The key is to avoid sinking too much money into custom Android development by making small changes on existing hardware. See how customers use the product first and, then decide whether a custom device would add value. Use a non-custom device as long as possible. During that time you’ll learn what custom features to implement. The education is highly valuable in order to develop a meaningful custom Android product.

Already Using Mass Market Tier 1 Brand Tablets or Smartphones

Companies that are already using a tablet or smartphone from a tier 1 brand, often become interested in making a custom Android device after a few years. The main reason companies want to change from the mass market device is because they don’t have control over the supply. Every year the brand starts making a new model and discontinues an old model. The availability of stock is not stable. Also the company’s engineers need to modify their app’s code with each new version of hardware, adding burden and complications.

In this scenario, the company historical distribution data for the tier 1 brand device. Based on that it can predict the future volume for a custom device to determine if there’s enough volume to justify the up front cost of a custom product. It’s likely that the unit cost of a custom Android tablet, including amortized development costs, is lower than the unit cost of a tier 1 brand Android tablet. The custom device comes with higher up front costs though. For a well financed company that has a history using brand name Android tablets, developing a custom Android tablet is a smart business decision that has economic benefit within 1 year.

Using no-name brand

For companies running their custom business application on no-brand mass market devices, is a custom Android product even necessary? Some use cases don’t require any custom hardware. Maybe a bit of firmware customization on a generic device is all that’s necessary. Generic no-name brand devices are usually the cheapest products to source. The buyer needs to be sure that they’re getting products with good components, like new, grade A memory, a high quality battery, and quality assembly. In this scenario, the company can stick to buying ‘off the shelf’ devices, but should at least get a custom firmware made.

Minimum customization options should include restricting downloads, so end users can’t install unrelated apps. Embedding the client’s special apps in the firmware, so they’re always there, can’t be deleted, and will still appear after a factory reset. Custom branding, like a custom launcher or displaying the client logo on startup or on the wall paper of home screen.

Already using an existing custom product.

This is a great scenario to start from since there’s already experience with a custom product. Over time a company will discover aspects of their existing custom device that are either extraneous, missing, or could be optimized. These improvements will get integrated into a new design. Every 5-6 years it becomes necessary to update the hardware of a custom Android tablet because components used during the original development stage become obsolete over time.

When it starts to get difficult to source components of an old design, your product supplier should propose designing an updated version. If it’s not necessary to redo casing, and there aren’t major changes to the hardware, then updating should be fairly low cost and quick. Having a team that is already familiar with the product makes redevelopment easier. Since there’s historical volume of the existing custom product, it’s easy to predict future volume. As long as the volume is 5-10k+ pcs/year, updating the hardware may require a deposit on future volume, but shouldn’t require a high reinvestment.

Conclusion

For companies that have experience using a generic Android device to run their custom software, custom Android hardware not only delivers a better experience to end users, but also costs less than brand name alternatives. Benefits such as control over the devices’ operating system, embedded applications, and component selection are a few examples of where a custom Android device has clear advantages. Using a custom Android device is like wearing custom tailored clothes. They have the best look, fit, and feel, but you should know your style before getting something expensive made.