Concept Design for Hardware Products

20th June 2025 20/06/25
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Concept Design for Hardware Products: A Beginner’s Guide

Embarking on a hardware development project signifies a major commitment. Once you’ve made the decision to bring your concept to life and are ready to engage a design firm for prototyping, the natural question arises: What comes next?

Approaches to hardware design vary significantly across organizations and individuals. While the “one engineer, one board” model can succeed even in highly complex designs, it is typically suited to experienced, self-motivated designers. Conversely, some firms opt for a collaborative model—dividing the workload among multiple designers under a “one team, one board” philosophy. In this case, a lead designer oversees the entire project, while other team members are tasked with specific, well-defined hardware blocks and engage jointly in system-wide debugging.

Regardless of structure, hardware projects involve cross-disciplinary teams. These may include experts in software, FPGAs, mechanical systems, power supplies, and more. Hardware engineers are integrated as dedicated contributors within the broader R&D group to ensure seamless collaboration across domains.

Some designers thrive with mentorship—relying on experienced colleagues for guidance and direction. Others prefer a self-directed path, progressing through independent research and experimentation. This includes identifying problems, investigating root causes, and implementing solutions grounded in literature, experience, and intuitive reasoning.

The Importance of Hardware Design

Hardware design plays a pivotal role in the modern technological landscape. It serves as the foundation for virtually all electronic devices, from handheld smartphones to advanced computational platforms. It is the transformative process that converts theoretical concepts into functional systems, providing the infrastructure upon which software applications operate.

In the development of complex systems, a divide-and-conquer methodology is often employed:

The system is partitioned into smaller, manageable modules
Each module is designed and simulated individually
Modules are integrated and mapped physically onto PCBs, PLDs, or custom chips using CAD tools
Timing simulations are performed to detect and correct performance bottlenecks

A robust hardware design performs reliably on the first iteration. Achieving this requires a methodical design process, particularly for intricate systems. Simulation and formal verification before fabrication are crucial in identifying issues early. In practice, multiple prototype iterations are deployed in real-world conditions prior to full-scale production.

Modern hardware design is often managed through comprehensive databases containing all relevant details—custom circuits, PCB layouts, software versions, part specifications, and more. These databases streamline and partially automate the design process, though initial design decisions still require critical human input. These foundational decisions define the architecture of the product.

Creating a new hardware solution demands a top-down strategy. Starting with a precise specification of system requirements, the design is decomposed into functional modules. Each module must:

Serve a clearly defined purpose
Interact through standardized interfaces
Be independently testable

Unlike software, hardware modules often utilize differing technologies and present stronger incentives for reuse of proven components.

At LA NPDT, we provide the tools and support you need to succeed at every stage of your journey.

Fundamentals of Hardware Design

The hardware development process begins with a thorough understanding of system goals. This involves translating conceptual ideas into practical, functional architectures through rigorous planning and testing.

Key stages include:

Conceptualization: Define the system’s intended functions and operational parameters, including processing, memory, and I/O needs.
Schematic Design: Create detailed diagrams outlining electrical connections between components.
PCB Layout: Design the physical arrangement of components and trace routing, while addressing constraints such as signal integrity, board size, and thermal efficiency.
Prototyping: Fabricate an initial version of the design to validate functionality.
Testing and Debugging: Conduct thorough performance evaluations including power tests, signal analysis, and full system verification. Any defects are identified and rectified.

Product Requirements Document

Numerous clients approach us seeking a preliminary estimate by providing a brief overview of their concept. In reality, product design firms manage a wide spectrum of projects—from the most elementary to the highly complex. Given that no two projects are identical, a detailed Product Requirements Document (PRD) is indispensable to formally initiate the process and generate an accurate quote, authored by the hardware engineer, which outlines the product’s features, objectives, and challenges. Subsequently, a design plan is formulated and refined through trade studies and schematic/layout development. Often, the layout engineer is distinct from the hardware engineer, operating under their oversight. Ultimately, prototypes are commissioned and subjected to testing in collaboration with the software and FPGA teams.

Before the proposal is drafted, a formal requirements list or needs assessment is prepared. This assessment usually evolves into a series of architectural decisions that are iterative in nature and interdependent.

Design Planning Checklist

Main Functionality and Features: Detailed description of the board’s primary functions and features.
System Integration: Overview of the chassis or system in which the board will be incorporated.
Component Selection: Analysis of major device options including features, performance, limitations, and cost considerations.
Subsystem Diagrams: Block diagrams representing all subsystems.
Power Analysis: Spreadsheet detailing power rail specifications along with current and power calculations.
FPGA Reports: Preliminary reports on FPGA power consumption and physical fit.
System Initialization: Documentation of the system initialization sequence.
Programming Sequence: Detailed programming sequence for device configuration.
I/O Mapping: Tables outlining port and I/O-bank mappings.
Non-Plug-and-Play Access: Documentation for devices that do not support plug-and-play functionality.
Software Customization: Requirements for any customized software.

Glue Logic Specifications: Features for glue logic and system management, including descriptions of programmable registers for FPGA/CPLD-based solutions.
ASIC Reference Deviations: Differences from the ASIC reference design for BIOS/OS implementations.
Power Sequence Requirements: Specifications for the sequential power-up of system components.
PCB Layout Analysis: Floorplan analysis and flow-plan documentation for the PCB.
Signal Integrity (SI): Overview of all SI-related work both completed and planned.
VRM Circuits: Documentation for voltage regulator module auto-generated circuits.
SERDES Loss Budget: Calculations pertaining to the loss budget of SERDES links.
Mechanical Construction: Specifications related to the mechanical structure.
Thermal Analysis: Results from thermal management studies.
PCB Stackup: Preliminary stackup sketches.
Manufacturability Issues: Identification of any manufacturability concerns related to the PCB.

Design for Test (DFT) involves incorporating specific features in the hardware that facilitate functional testing and signal probing. It is important to distinguish between production DFT and engineering validation DFT. A prudent strategy is to identify the most critical test signals at an early stage and ensure that physical access for probing is incorporated into the design.

Design for Debugging (DFD) addresses the inherently unpredictable aspects of prototype bring-up. By expediting the identification and rectification of hardware bugs, DFD minimizes time loss and mitigates the risk of launch delays.

Prototyping

Rather than exclusively designing circuits for direct customer shipment, our process emphasizes prototyping as a preliminary step. Prototype testing is conducted to determine the necessary design refinements and to identify and correct any bugs—such as incorrect values or improper connections. Although design reviews significantly reduce the occurrence of errors, they cannot eliminate them entirely. Testing typically commences upon receipt of the prototypes, and it is common for initial iterations not to function as expected.

A typical hardware prototype is composed of four integral components:

An enclosure manufactured from materials such as plastic or metal.
A printed circuit board (PCB) or other pertinent electronic assemblies.
Firmware running directly on the electronic device.
Software, operating on a PC or mobile device, that facilitates interaction with the hardware.

Organizations seeking expert guidance in launching their products are encouraged to consult LA NPDT for comprehensive support in strategic planning and execution. Visit LA NPDT to learn how we can help you optimize your product launch checklist and achieve your business goals.

Overview of Key Hardware Design Concepts

There exists a wide array of hardware design concepts; herein, three principal concepts are examined.

Functional Product Concept

In modern markets, the emphasis has shifted from the hardware itself to the overall value a product delivers to the customer. However, the definition of product value remains a nuanced matter. Functional products prioritize intangible customer requirements, with success now measured primarily by customer satisfaction rather than solely by traditional, quantifiable specifications. An integrated, process-oriented approach that unifies various design processes is essential, as the hardware serves merely as one element in the overall value equation. The balance between service and hardware is determined on a case-by-case basis, and design decisions significantly influence the established requirements.

Hardware–Software Co-Design Concept

Originating in the 1990s, the hardware–software co-design paradigm is founded on a unified design language that encompasses both hardware and software domains, supported by a common simulation and synthesis framework. It is critical to avoid premature segregation of functionality between hardware and software. Instead, the design process should support flexible development alongside intensive interaction and iterative feedback between the two disciplines (Figure 1).

Modern methodologies require that:

Representation and simulation tools be unified.
Hardware and software development proceed in parallel.
Final partitioning decisions be informed by insights gained during implementation.

This integrated approach is particularly pertinent in the fields of artificial intelligence and machine learning, where adaptability and scalability are paramount.

Design for Manufacturability (DFM) Concept

Design for Manufacturability is a strategy that ensures a product can be efficiently and reliably manufactured at scale. By proactively identifying and mitigating potential manufacturing obstacles during the design phase, DFM minimizes production costs, reduces time-to-market, and alleviates production challenges. Key distinctions between DFM and traditional hardware design include:

Consideration of manufacturing processes, including machinery, fabrication techniques, and inherent constraints.
An emphasis on optimizing design primarily for production efficiency rather than solely for functionality.
A focus on simplifying assembly, standardizing production processes, and reducing component counts.
The achievement of scalability and reproducibility, ensuring designs can be effectively produced in high volumes.
Cost reduction through the adoption of simplified designs and economical materials.

Conclusion

Hardware design is a foundational discipline that drives technological innovation and underpins the development of sophisticated electronic systems. A detailed understanding of its core principles, methodologies, and emerging trends enables engineers and practitioners to create systems that are efficient, reliable, and state-of-the-art.

In essence, hardware design forms the backbone of modern technology by transforming conceptual ideas into tangible, functional devices that influence daily life. Mastery in this realm requires a harmonious blend of creativity, technical expertise, and an unwavering commitment to excellence. As technological landscapes continue to evolve, hardware design remains at the forefront of innovation—shaping the future of industries through its emphasis on functionality, efficiency, scalability, reliability, and interoperability.

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