PCB Assmebly Prototype
PCB Assembly Prototype is one of the most important steps from concept to reality products, Eashub supports product stages from concept, EVT to PVT on PCBA prototype. EVT – DVT – PVT acronyms stand for the different stages of product engineering and industrialization. These phases of prototype development exist to minimize risks, defects, errors, bugs and design flaws before entering mass production. It is extremely important to identify and cope with these risks during the engineering design phase, otherwise producing and selling faulty products would cost you a lot more in money and reputation.
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EVT (Engineering Validation Testing)EVT Succeeds after the first concept prototype. EVT phase takes up a series (or even a small batch) prototypes of various modules (or subsystems). EVT is all about developing work-like and (sometimes) work-like + look-alike prototypes to validate test and refine the core functionality of the product. These prototypes can be anything between a breadboard electronics prototype, PCBA and functional prototype with a 3D printed enclosure. EVT is intrinsically iterative and several iterations can be made before you eliminate design flaws through functional testing and analysis.
Objective: EVT is to combine look-alike and work-like subsystem prototypes made of intended components to meet the functional requirements in the form factor as per your PRD (product requirements Document).
Prototype Quantities: 3-50 units, depending on the design complexity and BOM cost. On average, 5-12 prototypes are required to complete the EVT.
Technologies: 3D printing, laser cut/milled PCBs, soft tooling (silicon molds), professional hardware development kits (HDK), rapidly cut/milled parts.
Deliverables: fully-functional prototype with key components performing as intended.
Limitations: Prototypes delivered throughout the EVT phase may look somewhat ugly, raw and have a lack of beautiful cosmetic finish. The EVT prototype can also miss some non-key mechanical features such as handles, curves in enclosure, painting, etc.
Only after completing the EVT phase one really pushes on with the industrial design to develop the product final appearance. Any industrial design before that stage is not relevant to the actual sizes, weight and module arrangements. The late alpha “work-like + look-alike” prototypes intend to realize the real look of industrial design.
DVT (Design Validation Testing)
DVT serves the need to validate the developed product’s design and start to implement DFM (design for manufacturability) along with other DF-X rules. After completing EVT prototyping, one should lock on to deliver the design of the prototypes and enclosures that look like the final product.
It is the last stage before commencing sales and one need to make sure the design is compliant with the various standards and certification requirements for targeted markets: CE, EC, FCC, UL, RoHS, REACH, CCC etc. And here again, it is important that your product comply with the electric current source before you finalize the design and apply for certification. There can be several DVT iterations, and different DVT prototypes can be delivered. These range from hand-crafted expensive prototypes with a fine finish to a small batch produced with “quick” and/or conventional steel models in the injection modeling machine.
Objective: DVT is to fix the design (i.e. dimensions, weight, materials, finish, moving mechanical parts) and rationalize the final product’s features.
At this stage you should carefully revise and consider features vs product quality/finish vs production and BOM cost vs production volume; Complete the necessary certifications; Develop and finalize boxing and packaging; Commence to request RFQs from mass-producers and devise plans for logistics.
Prototype Quantities: typically 20-200 units, depending on the design complexity and BOM cost. The prototypes will be used for various reasons: certification lab tests, “beta tests” with early customers/testers.
Technologies: 3D printed + gel-coated enclosures with the finish “as from the factory”, rapidly cut/milled parts; industrial equipment (e.g. injection moulding) and 1st generation tooling (e.g. “quick moulds”).
Deliverables: functional prototypes ready for mass-production with BOM and a design documentation package. Boxing and Packaging design completed. Estimate mass-production yields
Limitations: The DVT prototypes and documentation is nearly final and can be slightly changed further in development. Some mechanical parts and electronic components may not be final due to economic reasons.
PVT (Product Validation Testing)
PVT is the last step before officially commencing to mass-production. Usually 5-10% of the production run is delivered in the PVT, aiming to stabilize the quality of the manufacturable product.
Although the PVT is not the most expensive stage, the outcomes may have a crucial impact on quality and the cost of volume production. Only minor changes are allowed at the PVT. Any significant change in design kicks the project back to DVT. Prototypes released at this phase are also called “Betas” and samples acquired from the mass-producer referred to as “golden samples”. The DF-X undergoes some corrections which result in mould and tooling development. Test benches for PCBA tests are designed. All components, materials, packaging and logistics are planned at this stage.
Objectives:
• Verify mass-production yields;
• Finalize DF-X with the help of CM aiming to minimize waste and make assembly more efficient;
• Make the first pilot production run and ensure the product quality adheres to your expectations;
• Weed out the last design flaws during the pilot production run;
Prototype Quantities: PVT prototype quantities typically range between 50 and 500 in order to verify mass-production yields and provide product samples.
Technologies: Industrial technologies suitable for volume production only;
Deliverables: Final product produced in a limited quantity by using the tools for mass-production. Electronic layouts and components are revisited using PCB stencils for soldering components. Mechanical DFM is finalized and plastic parts are manufactured by using 2nd generation moulds.
Duration: 3-6 months in general.
Limitations: The time required to design and produce custom tools is generally long.
Mass-production (MP)
This means that you have placed your purchase order (PO) and agreed on the production quantities with the CM
MP is typically started from 1000-2000 units which undergo quality and functionality testing. This is ensured via QC (quality control) and QA (quality assurance) measures. Now you are left with the “simple things” which are sales, customer support and service, dealing with product returns and defects and thinking about the next product version. And do not forget about the end of lifecycle (EOL) which entails following various disposal procedures and waste management protocols while thinking of replacing your old product with a new SKU! While prototype assembly typically consists of a limited production run, but we offer consistent same quality standard together with our solid experience on NPI control, that is not only support by dedicate NPI production lines, but also on the solid basis of many check points of new products.
Eashub can get your PCB assembly prototype done in a few days with rational price, which allows you can evaluate immediately and move quickly to next stage. We’re able to commit with our flexible assembly business model, leading data algorithm, mega data channel, and high-quality control standards. To get PCB assembly Prototype quote for your product, please click the following button and upload your circuit spec and BOM. We will response the RFQ in 48 hours.
Need guidance? Here are some helpful resources
• PCB Assembly Checklist
• BOM Template
