Product development · DFM and production
Design for manufacturing (DFM) and small-batch production
For a product that already works: Conceptech reviews the design for DFM and DFT, looks for BOM savings, prepares the manufacturing pack and takes a pilot run and first batch through with the manufacturers.
Incoming inspection, integration and testing for small batches, in our lab
- For
- Teams with a working prototype, before the move to production or to a new manufacturer
- What you get
- A DFM review, a complete manufacturing pack, a pilot run and follow-through with manufacturers
- First step
- A call with an engineer about the product, its stage and quantities, then a written proposal
DFM review
What does a DFM review check?
A DFM review checks whether the product can be made, assembled and tested again and again, at consistent quality and a sensible cost. These are the topics we go through before you order in volume.
The board: PCB fabrication
Board assembly
Components and BOM
Mechanical parts and enclosure
Wire harnesses
Production testing, DFT
Manufacturing pack
Manufacturers we work with
Who makes it, and what do we handle around production?
The parts are made by established manufacturers we work with. We prepare the files, order, follow up and inspect, so you have one point of contact from the design file to a tested unit.
What we handle around production
- A DFM review of the boards, mechanics and harnesses before the order
- A complete manufacturing pack: Gerbers, BOM, assembly drawings and test procedure
- Ordering and follow-up with the manufacturer, from technical queries to shipping
- Incoming inspection, integration and testing in our lab, for small batches
- All purchasing and manufacturing handled on your behalf, if you prefer
| Capability | Stages | Made with |
|---|---|---|
| PCB fabrication and assemblyPCB fabrication, assembly, component sourcing and testing |
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| Mechanical parts and enclosuresCNC, 3D printing, rapid injection moulding, die and vacuum casting, and sheet metal: laser cutting, bending, welding |
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| Wire harnesses and cable assembliesCustom wire harnesses and cable assemblies built to drawing, from prototype to production |
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PCB fabrication and assembly
PCB fabrication, assembly, component sourcing and testing
- Stages
- PrototypeSmall seriesProduction
- Made with
- Nistec
- OurPCB
Mechanical parts and enclosures
CNC, 3D printing, rapid injection moulding, die and vacuum casting, and sheet metal: laser cutting, bending, welding
- Stages
- PrototypeSmall seriesProduction
- Made with
- HLH Prototypes
- Zitec
Wire harnesses and cable assemblies
Custom wire harnesses and cable assemblies built to drawing, from prototype to production
- Stages
- PrototypeSmall seriesProduction
- Made with
- Cloom Tech
- OurPCB
In Israel we work with Nistec for PCB assembly and production when the work is urgent or sensitive, and with Zitec for enclosures and sheet-metal parts.
First batch
First batch: a pilot run before the big order
A small batch reveals what a prototype doesn't: parts that don't fit, assembly steps missing from the documentation, and tests that don't catch faults.
Before ordering in volume, we build a small batch with the same manufacturer, the same manufacturing pack and the same test procedure that production will use. Problems surface while they are still cheap to fix.
- First-article inspection: the first units are checked against the drawings, the BOM and the test procedure before the manufacturer continues with the rest of the batch.
- Incoming inspection, integration and testing: for small batches we can do all of this in our lab, and keep a result for every unit by serial number.
- Yield tracking: we record how many units pass first time and the cause of every failure, then fix the design or the process before the next batch.
As quantities grow, the same test procedure moves to an automated test station at the manufacturer or on your line. Automated test stations for production
Certification
Certification before production: when to go to the lab?
Certification tests are run on units identical to the product you will manufacture. A design change after approval can mean testing again.
The order that works: pre-compliance tests on the prototype, testing at an accredited lab on units from the pilot run or close to it, and only then an order in volume. That way any change the lab requires, such as extra filtering or a different component, goes into the manufacturing pack before you build in quantity.
Even swapping a component for availability after approval can mean a retest. So we mark alternative parts in the BOM early, and ask the lab what triggers a retest before anything changes.
Certification readiness for electronic products
DFM and production are one part of our product development work. All hardware product development services
DFM and small-batch production: FAQ
Where are the parts made?
Most parts are made by established manufacturers in Asia that we work with: OurPCB for PCB fabrication, assembly and component sourcing, HLH Prototypes for mechanical parts, and Cloom Tech and OurPCB for wire harnesses and cable assemblies.
In Israel we work with Nistec for PCB assembly and production when the work is urgent or sensitive, and with Zitec for enclosures and sheet-metal parts.
The control stays with us: a DFM review before the order, a complete manufacturing pack, follow-up with the manufacturer, and for small batches, incoming inspection, integration and testing in our lab.
Who manages the relationship with the manufacturer?
We do. We handle the order, the manufacturer's technical queries, file and sample approvals and the follow-up through to shipping, so you have one technical contact for the whole chain. If you prefer, we handle all purchasing and manufacturing on your behalf.
If you have your own manufacturer, or prefer to order directly, the manufacturing pack makes that possible too. Ownership of the files is agreed in the contract for each project.
How are parts checked when they arrive from the manufacturer?
For small batches we can do incoming inspection, integration and testing in our lab. We check the parts against the drawings and the BOM, integrate the boards, assemblies and harnesses into a working product, and run the agreed test procedure on every unit.
Results are kept by serial number, and every finding goes back to the manufacturer with documentation. At higher volumes the testing moves to a test station at the manufacturer or on your line.
How long does a small production batch take?
It depends on the process and the quantity, so the schedule is estimated after the DFM review, not before. The main factors are component availability, the process (boards, machining, an injection mould or harnesses), the number of sample rounds, and shipping.
For urgent orders, parts can be made by manufacturers in Israel. The estimated schedule is part of the proposal.
What if the project is sensitive or confidential?
Sensitive projects can be made in Israel instead of sending files abroad: PCB assembly and production at Nistec, and enclosures and sheet-metal parts at Zitec. We sign an NDA on request when the project calls for it, and we agree with you in advance which files go to each manufacturer. Ownership of the files is agreed in the contract for each project.
What drives the cost of a small production batch?
The cost depends on the product and the quantity, so you get a written proposal after the DFM review. The main drivers:
- The quantity, and one-off costs such as an injection mould or a test fixture
- The board: size, layer count, component count and any hand assembly
- Component availability and the need for alternative parts
- The process for the mechanical parts and the complexity of the harnesses
- How much is tested on each unit, and how urgent the order is
Parts and manufacturing can be included in the project cost or handled separately, whichever suits you.
Tell us about your product, and we'll say what production needs
Describe the product, its current stage and the quantities you plan to build. An engineer will go through what you sent and reply with an initial direction.
Usually a reply within 3 working hours, by email or phone