Evaluate existing products to determine which components (like camera, screen, CPU, memory, etc) to use in final hardware architecture. (1 month)

The basic external design of the casing. This part is completed by the client. If client doesn’t have their own designer Hatch can introduce one. Hatch provides information about component dimensions to designer. Once an initial ID is done Hatch will build the PCBA around the design. ID usually requires modification during the development process. The development process begins once ID is complete.

Confirm schematic and create the PCB layout and select specific components. This process happens after Hardware Architecture Validation. (1.5 months)

After initial PCBA samples are ready the firmware engineers can start testing custom firmware code on the new hardware. Initial firmware customization can start using a generic PCBA (from an existing product that’s similar in architecture to the custom Android product), but the most crucial engineering and testing begins once the initial PCBAs are ready. (1 month for first version; 2-3 more months for optimization. Android OS modification often goes on until mass production and sometimes after.)

After deciding the specs of each component Hatch will decide which specific model to use and which specific supplier to purchase from. During the prototype and trial production stages client must approve the results of the components chosen. If any components don’t provide the desired result Hatch will work to optimize the result or offer an alternate component for a new evaluation. (3 weeks for first version; ongoing changes are common for various reasons)

Creating steel molds that are used for mass production plastic injection or die-cast molds for mass production of metal parts for the product case or internal parts. (5 weeks until initial samples can be produced; modifications to molds can take another 1-2 months and happen in parallel with trial production(s))

While tooling happens Hatch will prepare electronic components for mass production including the PCB. Trial production is the first time that the product will be assembled on an assembly line, in a real mass production environment. This stage is crucial for many reasons including checking that the case design can be assembled efficiently and doesn’t have any problems, checking that all the parts, firmware, and drivers work together, optimizing manufacturing and quality control processes, testing the finished product, and making devices for end user testing and certification testing. Sometimes multiple rounds of trial production are necessary. Before trial production Hatch will assemble a limited number of PCBA (usually 50-200 pcs depending on individual needs of client/project) to limit risk in case an unforeseen change is needed to the electronics. Alternative to purchasing the full mass production quantity is to purchase a trial production quantity from the suppliers as a further measure to limit risk of unforeseen changes. Purchasing the smaller quantity still requires a deposit on the full quantity as suppliers want validation of a larger order and sometimes charge an additional service fee for below MOQ production. Considering these options the client and Hatch will decide the best path forward when the time comes to make a decision. Preparing components for trial production happens in parallel with tooling. (2.5 months)

While all products have a generic assembly process your custom product will have caveats about it which are different from any generic product. Hatch combs through each stage of the manufacturing process to ensure that the specific details that apply to your product are communicated in a formal document so the factory will set up the necessary work stations and factory workers are aware of what to do. This process happens during and after trial production, in parallel with trial production testing. (2 weeks for initial SOP, with updates as needed)

Devices from trial production are used for testing and optimization by several parties. Usually 3-4 units go to the electronics and firmware engineers, 8-10 units go to the certification lab, Hatch keeps 3 units, the client holds units for internal testing, and sends units to end users for testing. The client will decide how many units they want for internal and end user testing. (1 month shipping and testing, 1 month for modifications, rest of timeline depends on nature of the changes)

Cost estimates for certification can be provided at the beginning of a project, but actual costs will be confirmed before trial production begins. Units from trial production get sent to the certification lab for testing. Certification requirements often change during the development process as clients find new business opportunities in different parts of the world or decide to focus only on specific parts. Different regions/countries have different certification requirements. Clients can use Hatch to manage the certification process or handle the certifications on their own. Labs almost always find problems that require revision. For this reason extensive interaction between the lab and engineers is required to make necessary adjustments to the electronics or firmware. Using Hatch for to handle certification testing is usually faster and cheaper in the end.