There is a well-known phrase in the world of technological innovation: “Hardware is hard.” And it’s no coincidence. Hardware development is a long, complex process full of variables that cannot always be predicted.
Unlike software, where many problems can be solved with an update, hardware errors often involve redesigning parts, manufacturing new prototypes, or repeating entire validation processes within the product development process.
At I-MAS, after more than two decades of participating in the design and development of technological products, we have identified a series of mistakes that appear time and time again in startups, industrial companies, and even large corporations. Knowing them can help avoid delays, cost overruns, and, in some cases, the complete failure of the project.
1. Underestimating development time
One of the most common mistakes is to think that a hardware product can be developed in a few months.
The reality is that there are many phases involved in product development: industrial design, product engineering, electronics, prototyping, validation, certification, and finally product industrialization. Each of these phases usually requires iterations.
That is why, in many projects, the actual deadline ends up being much longer than initially estimated.
2. Designing a product for a passing trend
Hardware development requires time and investment. If the product depends on a very specific trend, there is a risk that by the time it reaches the market, that opportunity will have already disappeared.
That is why it is essential to think about products with real market potential, especially when it comes to technological products.
3. Thinking that the prototype is already the product
When a prototype works in the lab, it may seem like the hardest part is already done. However, the leap from a working prototype to a manufacturable product is enormous.
Industrialization involves developing molds and tools, optimizing processes, and validating that the product can be manufactured consistently in mass production.
4. Not understanding economies of scale
The unit cost of a product depends largely on the volume of production.
Many projects set a target sales price without considering that achieving it may require producing thousands or tens of thousands of units.
If the initial volume is low, the cost per unit can skyrocket and make the business unviable.
5. Choosing the wrong technology partner
The development partner is a key player in any technological product development project.
A partner without real experience in product engineering or industrialization can cause delays, redesigns, and technical problems that are difficult to resolve.
It is important to work with teams that have proven experience in hardware development and real knowledge of the industrial environment.
6. Separate design from engineering
A product may look spectacular in a rendering but be impossible to manufacture.
Industrial design and product engineering must be developed in parallel from the early stages of the project to ensure that the product is attractive, functional, and viable for industrial manufacturing.
7. Patenting too early
Many entrepreneurs try to protect their idea from the outset of the project.
However, during hardware development, it is common for the product to evolve and change. If the patent is registered too early, it may end up protecting a version that will never reach the market.
8. Not validating the market
Passion for an idea can cause you to overlook a fundamental question: is there really a market for this product?
Before investing significant resources in development, it is advisable to validate interest through market research, user interviews, or pilot tests.
9. Misapplying the concept of MVP
The concept of Minimum Viable Product (MVP) originated in the world of software, where errors can be corrected quickly.
In hardware, this is not always possible. The first version of the product may be simple, but it must function perfectly in its main role.
10. Launching the product without sufficient testing
The pressure to launch the product on the market can lead to a reduction in the testing phases.
However, testing for strength, durability, and real-world use is essential for detecting faults before customers do.
A poorly validated product can lead to returns, technical service issues, and a significant negative impact on the brand.
How we approach hardware development at I-MAS
Developing a physical product involves combining engineering, design, manufacturing, and business strategy. Avoiding these mistakes reduces risks and significantly increases the chances of success.
At I-MAS, we have been supporting companies and startups in the development of new products for over 20 years, from the initial idea to industrialization.
In the chapter “Why 90% of HARDWARE PRODUCTS FAIL (and how to AVOID IT)” from Toque de Ingenio, the podcast sponsored by I-MAS, we delve much deeper into these common hardware development mistakes and how to avoid them when turning an idea into a real product.
If you are developing a new product or want to better understand the technical, strategic, and financial challenges that arise in these types of projects, you can watch the full episode on the Toque de Ingenio YouTube channel.
Discover how we can help you take your project to the next level at I-MAS. Contact us and take the first step towards innovation!
