So you’ve done the research and development on some prototype and have a working PCB and a plan for an enclosure, but is the job really done? After a working proof of concept version of a circuit is done, the next step often is to apply various optimizations to the design to improve stability, reduce cost, or aid in the manufacturing and assembly process. Sometimes the need could be as simple as shrinking a design or reshaping a piece to fit the hand more nicely.
Minimization
Frankenstein Circuit
The Little Integrated Circuit That Could
Knock-On Effects
These components and PCB minimization can have secondary effects, many good but some others should be carefully considered. For example, the DIP and QFN variants of the ATmega328 controller have a 0.3milliAmp difference in power consumption levels at 4MHz and 3V power level. While smaller active components can be more efficient than their larger versions, one must remember that the smaller size means the smaller thermal mass of the whole part, meaning if the power regulator is expected to support a large amount of current, a through-hole version that can have a fin heatsink attachment and a fan could save the whole piece from overheating.
Simplification
Sometimes an operation is simple enough to not require the complexity level of the parts used for development. The ATmega328 controller is a great tool for development, but maybe a particular design could be done using less logical pins, and a $1.40 ATtiny85 or a 33¢ 555 timer IC could satisfy the needs of the design. A $1 RGB led might seem like a bad choice compared to the 81¢ total price for 3 LEDs, but the RGB LED can actually create 7 colors, giving the capacity for 7 unique indications while also consuming less PCB space.
Thinking about doing a product run of an optimized design? Find out our PCB capabilities here, or get a quote here, or call us at (888) 648-5071.