Prototyping That Moves You Forward
Prototyping fails when BOMs are fragile and documentation is incomplete. We help you stabilize component choices, plan alternates, and hand off clear manufacturing packages so your first builds teach you what matters—not what was missing.
We manage the full prototyping pipeline—from BOM preparation and component procurement through assembly coordination and first-article validation. Whether you need five boards for a proof-of-concept or fifty units for a pilot build, we handle the logistics so you can focus on your product.
BOM Optimization & Cost Engineering
Before a single board is fabricated, we perform a thorough BOM review to identify cost-reduction opportunities without compromising performance. This includes evaluating passive component value consolidation (reducing unique part numbers), identifying drop-in replacements for high-cost or long-lead-time components, and verifying that every line item has adequate stock across authorized distributors. We cross-reference against Digi-Key, Mouser, Arrow, and Avnet inventory in real-time and flag any components with lifecycle concerns (NRND, limited availability, single-source).
For cost-sensitive projects, we provide a tiered BOM analysis showing per-unit cost at prototype quantities (1–25 units), low-volume production (100–500 units), and volume production (1,000+ units), so you can make informed decisions about component selection early in the design process.
Component Sourcing & Supply Chain Management
Supply chain disruptions have become a persistent challenge in electronics development. We mitigate procurement risk by maintaining relationships with authorized distributors, identifying second-source components during the design phase, and tracking lead times throughout the procurement cycle. For hard-to-find or allocated parts, we can evaluate pin-compatible and functionally equivalent alternatives, performing the necessary electrical analysis to validate substitutions.
All components are sourced exclusively from authorized channels to ensure authenticity and traceability — we never use grey-market or broker-sourced parts for prototype builds.
Assembly Coordination
We prepare complete assembly packages including Gerber files, pick-and-place centroid data, assembly drawings with polarity and orientation call-outs, stencil specifications, and any special process instructions (selective soldering, press-fit connectors, conformal coating areas). We coordinate directly with the assembly house to resolve any DFA questions before the build starts, minimizing delays and rework.
For mixed-technology boards that combine SMT, through-hole, and hand-solder components, we define the assembly sequence and identify which operations require manual intervention versus automated placement.
Prototype Validation & Testing
Once boards arrive from assembly, we perform structured bring-up and validation:
- Visual Inspection — IPC-A-610 workmanship review under magnification, checking solder joint quality, component orientation, and marking legibility.
- Power Rail Verification — Sequential power-up with current limiting, measuring each voltage rail against design targets and verifying regulator stability under load.
- Functional Testing — Exercising each subsystem: communication interfaces, sensor inputs, actuator outputs, user interface elements, and wireless links.
- Performance Characterization — Measuring key parameters (clock accuracy, ADC linearity, output power levels, current consumption in each operating mode) against specification.
- Boundary Condition Testing — Evaluating behavior at voltage extremes, temperature boundaries, and maximum load conditions to identify design margin.
What We Deliver
- Optimized, costed BOM with distributor part numbers and stock availability
- Complete assembly package ready for your CM or our partner facilities
- Assembled and inspected prototype boards
- Power rail verification report with oscilloscope captures
- Functional test results and deviation log
- Recommendations for design revisions based on prototype findings
- Component lead-time and lifecycle risk summary