Concept Refinement: Industrial Design and User Experience (UX) Optimization

By Srihari M, Director Product Development at EurthTech

Published on March 18, 2025

With the Discovery Phase complete and a Proof of Concept (PoC) validated, the next step in product development is the Concept Refinement Phase. This stage focuses on optimizing the product’s design to enhance usability, manufacturability, and overall user experience before transitioning to full-scale engineering.

A well-executed Concept Refinement phase ensures that:

• The product is aesthetically and functionally optimized for its intended users.

• Manufacturing constraints are identified and addressed early.

• User interactions are intuitive and streamlined.

• Compliance with regulatory and environmental standards is considered.

This article is the first in a four-part series exploring Concept Refinement. In Part 1, we focus on Industrial Design and User Experience (UX) Optimization, covering:

1. The Role of Industrial Design in Product Development

2. Key Principles of Good Industrial Design

3. Enhancing User Experience (UX) in Hardware Products

4. Prototyping and Iteration for Design Validation

   
   

1. The Role of Industrial Design in Product Development

Industrial design plays a critical role in ensuring that a product is not only functional but also ergonomic, visually appealing, and user-friendly. This discipline blends art and engineering to create a seamless interaction between users and technology.

Why Industrial Design Matters:

• User Adoption: A well-designed product encourages faster adoption and reduces the learning curve.

• Brand Identity: A unique and recognizable design strengthens a company’s presence in the market.

• Competitive Advantage: Differentiation in design can be a major selling point.

• Manufacturing Efficiency: Design choices impact production processes, material selection, and cost-effectiveness.

Example: Apple’s iPhones are not just powerful smartphones; they are meticulously designed to offer premium aesthetics, intuitive usability, and a seamless tactile experience.

2. Key Principles of Good Industrial Design

An effective industrial design process must consider functionality, aesthetics, manufacturability, and user comfort. Below are key principles:

a) Simplicity and Minimalism

• Avoid unnecessary complexities that could confuse users.

• Focus on essential elements while maintaining high usability.

• Example: Dyson vacuum cleaners prioritize sleek, ergonomic designs with intuitive controls.

b) Ergonomics and Human Factors

• Ensure the product is comfortable and efficient for prolonged use.

• Consider grip, weight distribution, and control placement.

• Example: Gaming controllers are shaped to fit hands comfortably for long periods.

c) Material Selection and Durability

• Choose materials that provide strength while minimizing weight and cost.

• Consider resistance to temperature, impact, and environmental factors.

• Example: Outdoor IoT sensors require IP-rated enclosures to withstand harsh conditions.

d) Manufacturing and Assembly Efficiency

• Optimize the design to reduce part count and simplify assembly.

• Consider tooling feasibility (injection molding, CNC machining, etc.).

• Example: Tesla’s Gigafactory reduces manufacturing costs by designing large, single-cast body frames.

e) Sustainability and Eco-Friendly Design

• Use recyclable or biodegradable materials when possible.

• Reduce electronic waste by allowing easy repair and component upgrades.

• Example: Fairphone designs modular smartphones to extend product lifespan.

3. Enhancing User Experience (UX) in Hardware Products

UX in hardware products is about ensuring that users can intuitively understand and interact with the product without extensive training.

Key UX Factors to Consider:

a) Interface Design and Feedback Mechanisms

• Visual Cues: LED indicators, e-ink displays, or OLED screens for status updates.

• Audio Feedback: Beeps, alerts, or voice prompts to guide the user.

• Haptic Feedback: Vibration-based confirmations for actions.

Example: A smart home thermostat should have a simple touchscreen interface with clear visual indicators, making temperature adjustments effortless.

b) Ease of Installation and Setup

• Provide clear instructions or QR-code-based onboarding tutorials.

• Minimize the number of steps required for first-time setup.

• Example: Amazon Echo devices use a mobile app-guided setup to simplify Wi-Fi pairing.

c) Intuitive Controls and Interaction

• Reduce the number of buttons to only what’s necessary.

• Prioritize gesture-based or voice-controlled interactions for hands-free use.

• Example: Modern smart TVs rely on minimalist remote controls with voice assistants like Alexa or Google Assistant.

d) Safety and Error Prevention

• Prevent accidental activations with well-placed safety mechanisms.

• Use fail-safe designs to prevent user errors.

• Example: Industrial machinery includes two-step activation mechanisms to prevent unintended operations.

4. Prototyping and Iteration for Design Validation

Before finalizing the industrial design and UX, iterative prototyping is essential for real-world testing.

Prototyping Methods:

• 3D Printed Models: Evaluate ergonomics and form factor before committing to final manufacturing.

• Looks-Like Prototypes: Aesthetic models that help gauge user reaction.

• Works-Like Prototypes: Functional models with basic electronics for usability testing.

• Pilot Production Runs: Small-batch manufacturing to test assembly feasibility and real-world use cases.

Example of Design Iteration:

1. Version 1: A hand-held IoT scanner prototype may feel too heavy, leading to weight optimization.

2. Version 2: Improved grip and button layout enhance usability.

3. Final Version: Achieves optimal user-friendliness, weight distribution, and manufacturability.

Industrial Design and UX Optimization play a crucial role in hardware product success. By focusing on ergonomics, material selection, intuitive user interactions, and iterative prototyping, we ensure that the product is aesthetically pleasing, easy to use, and ready for scalable manufacturing.

Concept Refinement: Design for Manufacturability (DFM) and Component Selection

Following the Industrial Design and UX Optimization, the next step in the Concept Refinement Phase is to ensure that the product can be efficiently and cost-effectively manufactured at scale. This phase focuses on Design for Manufacturability (DFM) and Component Selection, both of which play a crucial role in minimizing production costs, improving product reliability, and streamlining the transition to mass production.

In this section, we will explore:

1. Understanding Design for Manufacturability (DFM)

2. Optimizing Mechanical Design for Production

3. Electronics Design and Component Selection

4. Supply Chain and Sourcing Strategies

   
   

1. Understanding Design for Manufacturability (DFM)

Design for Manufacturability (DFM) is the process of designing a product in a way that simplifies and optimizes manufacturing without compromising performance or quality.

Key Objectives of DFM:

• Reduce Manufacturing Costs: By simplifying part complexity and minimizing waste.

• Improve Production Yield: Ensuring high-quality, defect-free products.

• Enhance Assembly Efficiency: Reducing the number of steps and fasteners required.

• Ensure Scalability: Designing a product that can be easily ramped up for high-volume production.

DFM Principles for Hardware Products:

Principle	Description	Example
Minimize Part Count	Reduces material costs and assembly complexity	Using a single molded enclosure instead of multiple assembled parts
Standardize Components	Avoids custom parts that increase costs and sourcing complexity	Using standard screws instead of custom fasteners
Design for Automated Assembly	Optimizes for robotic or pick-and-place assembly	PCB layout designed for automated SMT assembly
Optimize Tolerances	Ensures manufacturability without overengineering	Allowing ±0.2mm instead of ±0.05mm where possible
Material Efficiency	Reduces material waste and improves sustainability	Injection molding with minimal excess material

2. Optimizing Mechanical Design for Production

The mechanical design should be optimized for cost, durability, and ease of assembly. This involves selecting the right materials, ensuring manufacturable geometries, and reducing complexity in tooling.

Key Considerations in Mechanical DFM:

• Injection Molding Feasibility:

  • Ensure uniform wall thickness to prevent warping.

  • Avoid undercuts that require expensive side-action molds.

• Material Selection:

  • ABS for general-purpose enclosures (strong, lightweight, cost-effective).

  • Aluminum for heat dissipation in industrial applications.

  • Silicone for waterproof seals in outdoor IoT devices.

• Ease of Assembly:

  • Snap-fit designs eliminate the need for screws or adhesives.

  • Modular designs allow for easy disassembly and repair.

Example:

A smart home sensor’s plastic enclosure should be designed with snap-fit mechanisms instead of screws to reduce assembly time and cost.

3. Electronics Design and Component Selection

Selecting the right electronic components is critical for performance, cost, and longevity. Poor component selection can lead to supply chain issues, increased BOM costs, and regulatory failures.

Key Factors in Component Selection:

• Lifecycle Availability: Choose components with long-term availability to prevent redesigns.

• Power Efficiency: Select low-power MCUs and sensors to extend battery life.

• Certifications & Compliance: Ensure components meet RoHS, FCC, CE, UL standards.

• Cost vs. Performance Trade-Offs: Avoid over-specifying components to keep costs low.

Optimizing PCB Design for Manufacturability:

• Minimize PCB Layer Count: Keep to 2-layer or 4-layer PCBs where possible.

• Use Surface-Mount Technology (SMT): Reduces manual soldering and improves precision.

• Ensure DFM-Friendly Layouts:

  • Maintain adequate spacing between components for soldering.

  • Use test points for easy debugging.

  • Route traces efficiently to avoid crosstalk and EMI issues.

Example:

For an IoT-based battery-powered sensor, selecting an ESP32 low-power variant reduces power consumption while maintaining Wi-Fi/Bluetooth functionality.

4. Supply Chain and Sourcing Strategies

Efficient sourcing and supply chain planning ensure cost stability, availability, and resilience against disruptions.

Strategies for Reliable Sourcing:

• Dual Sourcing: Always have two suppliers for critical components to avoid shortages.

• Use Local Suppliers When Possible: Reduces lead times and logistics costs.

• Negotiate Volume Discounts: Early bulk orders reduce per-unit costs.

• Plan for Component Lead Times: Avoid delays by sourcing parts with long procurement cycles (e.g., MCUs, semiconductors).

Common Supply Chain Risks and Solutions:

Risk	Solution
Component Shortages	Pre-book inventory with suppliers
Geopolitical Disruptions	Diversify sourcing across different regions
Quality Variability	Work with ISO-certified manufacturers
Price Fluctuations	Lock in prices with long-term contracts

Example:

A company designing an industrial IoT gateway sources its MCU from two different manufacturers (STM32 and NXP) to avoid single-vendor dependency.

Design for Manufacturability (DFM) and Component Selection are essential for creating a product that is cost-efficient, scalable, and ready for high-volume production. By optimizing mechanical design, selecting the right electronic components, and ensuring a robust supply chain, companies can reduce risks and improve profitability.

Title: Concept Refinement: Environmental and Compliance Considerations

As product design advances through the Concept Refinement Phase, ensuring compliance with environmental, safety, and regulatory standards becomes a key priority. Products that fail to meet compliance standards face legal restrictions, safety concerns, and market entry barriers. Addressing these considerations early in the design phase minimizes costly redesigns and certification delays.

In this section, we will explore:

1. Understanding Regulatory and Compliance Requirements

2. Safety and Electrical Compliance Considerations

3. Environmental Standards and Sustainability Practices

4. Testing and Certification Strategies

   
   

1. Understanding Regulatory and Compliance Requirements

Compliance with industry regulations ensures market acceptance, consumer safety, and legal approval. Different industries and regions have unique regulatory requirements that products must adhere to before they can be sold or deployed.

Common Regulatory Requirements by Category:

Regulation	Description	Applicability
FCC (USA)	Regulates electromagnetic interference (EMI) for electronic devices	Wireless and RF-enabled devices
CE Marking (EU)	Ensures products meet health, safety, and environmental protection standards	Consumer and industrial electronics
RoHS	Restricts the use of hazardous substances in electronics	All electronic hardware
UL/IEC 62368-1	Electrical safety standard for IT and audio-visual equipment	Battery-powered and plugged-in devices
ISO 9001	Quality management system standard	Manufacturing and process control
IP Ratings (Ingress Protection)	Classifies the level of protection against dust and water	Outdoor and industrial products

Early identification of applicable compliance standards prevents unnecessary revisions later in the production cycle.

2. Safety and Electrical Compliance Considerations

Safety compliance is essential to prevent hazardous failures, electrical risks, and mechanical failures. Regulatory bodies impose strict electrical safety standards to ensure user protection.

Key Safety Design Considerations:

• Overvoltage and Short-Circuit Protection:

  • Use fuses, TVS diodes, and resettable circuit breakers to prevent electrical failures.

• Thermal Management:

  • Implement heat sinks, cooling fans, or passive ventilation to prevent overheating.

• Grounding and Isolation:

  • Use proper PCB design practices to minimize ground loops and EMI interference.

• Battery Safety Compliance:

  • Ensure compliance with IEC 62133 and UN38.3 for lithium-ion batteries.

Example:

For an IoT gateway, proper EMI shielding and electrical grounding can prevent RF interference, ensuring FCC compliance for seamless wireless operation.

3. Environmental Standards and Sustainability Practices

Eco-friendly design reduces the environmental impact and ensures compliance with global sustainability laws. Companies must consider material selection, recyclability, and energy efficiency in their design process.

Key Environmental Regulations and Design Strategies:

Regulation	Purpose	Design Considerations
RoHS (Restriction of Hazardous Substances)	Eliminates lead, mercury, and cadmium in electronics	Use RoHS-certified components
WEEE (Waste Electrical and Electronic Equipment Directive)	Promotes recycling and responsible disposal	Design for easy disassembly and recyclability
Energy Star	Improves energy efficiency	Use low-power components and optimize firmware for energy savings
REACH (Registration, Evaluation, Authorization of Chemicals)	Restricts harmful chemicals in manufacturing	Source materials from certified suppliers
EPEAT (Electronic Product Environmental Assessment Tool)	Promotes sustainable electronics design	Design for longevity, modularity, and reparability

Best Practices for Sustainable Product Design:

• Material Selection: Use recyclable plastics and biodegradable components where feasible.

• Power Efficiency: Optimize firmware and circuit design for low power consumption.

• Reduce Electronic Waste: Use modular designs that allow easy repair and part replacement.

Example:

A battery-powered IoT sensor can improve sustainability by:

• Using solar-powered charging to extend battery life.

• Designing for tool-free disassembly to facilitate recycling.

4. Testing and Certification Strategies

To meet compliance requirements, products must undergo third-party testing and certification before market launch.

Steps for Successful Compliance Testing:

1. Pre-Compliance Testing:

   • Perform in-house testing to identify design flaws early before sending for certification.

   • Use EMI test chambers, thermal analysis, and vibration testing to validate robustness.

2. Third-Party Certification:

   • Partner with accredited labs such as UL, TÜV, Intertek, or SGS.

   • Submit necessary design documents (schematics, material lists, test results).

3. Field Testing & Validation:

   • Deploy pilot units in real-world environments to test reliability and compliance.

   • Collect user feedback and adjust design if necessary.

4. Regulatory Labeling & Documentation:

   • Ensure proper regulatory markings (FCC, CE, RoHS, etc.) on the final product.

   • Maintain compliance documentation for audits and approvals.

Example:

A smart home device must pass FCC Part 15 compliance to ensure it does not cause harmful radio frequency interference.

Addressing Environmental and Compliance Considerations early in the Concept Refinement Phase ensures that products meet safety, regulatory, and sustainability standards. This reduces market entry barriers, prevents costly redesigns, and ensures consumer confidence.

Concept Refinement: Cost Optimization and Supply Chain Planning

The final stage of the Concept Refinement Phase is Cost Optimization and Supply Chain Planning. As a product moves toward production, balancing cost-efficiency, quality, and scalability becomes critical. Without a strategic approach to cost and sourcing, a product may become too expensive to manufacture, face supply shortages, or suffer from unpredictable market fluctuations.

This section will cover:

1. Cost Optimization Strategies in Hardware Development

2. Reducing Manufacturing and Assembly Costs

3. Supply Chain Planning for Scalability and Risk Mitigation

4. Logistics and Production Planning

By implementing cost-effective design, material selection, and supply chain strategies, companies can increase profitability while maintaining high-quality standards.

1. Cost Optimization Strategies in Hardware Development

Cost optimization begins in the design phase, long before the first unit is manufactured. Smart decisions in component selection, manufacturing methods, and supplier negotiations can significantly reduce overall costs.

Key Cost Drivers in Hardware Products:

• Bill of Materials (BOM) Costs – Components, PCBs, enclosures, displays, connectors.

• Manufacturing Process Costs – Injection molding, CNC machining, PCB assembly.

• Assembly and Labor Costs – Hand assembly vs. automated assembly.

• Packaging and Distribution – Bulk shipping, retail packaging, compliance labeling.

• Regulatory and Certification Costs – FCC, CE, RoHS compliance testing fees.

Cost Reduction Strategies:

Strategy	Description	Example
Design for Cost Efficiency	Reduce unnecessary features that drive up costs.	Avoid high-end displays if an LED indicator suffices.
Optimize BOM Selection	Choose cost-effective components without compromising quality.	Use a widely available MCU instead of a premium variant.
Reduce PCB Complexity	Minimize layer count and optimize trace routing.	Stick to 2-layer PCBs unless high-speed signals require more.
Leverage Volume Discounts	Order components in bulk to lower per-unit pricing.	Purchase resistors/capacitors in reels instead of small batches.
Choose Cost-Effective Manufacturing	Select production techniques that balance cost and quality.	Use injection molding for enclosures instead of CNC machining.

By making these optimizations, companies can reduce hardware costs by 20-40% without compromising performance.

2. Reducing Manufacturing and Assembly Costs

Manufacturing and assembly costs significantly impact a product’s final price. Optimizing production methods can streamline assembly, reduce labor costs, and improve efficiency.

Manufacturing Process Optimization:

• Injection Molding for High-Volume Production – Lower cost per unit compared to 3D printing or CNC machining.

• Automated SMT Assembly for PCBs – Reduces human error and improves production speed.

• Design for Assembly (DFA) – Fewer screws, snap-fit enclosures, and modular parts for easier assembly.

Minimizing Assembly Complexity:

Issue	Solution
Too many screws or fasteners	Switch to snap-fit designs to eliminate screws.
Manual soldering of components	Use automated SMT pick-and-place machines.
Complex wiring harnesses	Reduce wire count with flex circuits or bus connectors.
Hand assembly of small parts	Consolidate parts to reduce manual handling.

Example:

A wearable IoT device switched from manual screw assembly to ultrasonic welding, reducing assembly time by 30% and lowering labor costs.

3. Supply Chain Planning for Scalability and Risk Mitigation

A well-structured supply chain ensures component availability, cost stability, and protection against disruptions.

Supply Chain Strategies for Hardware Products:

• Dual Sourcing for Key Components: Prevents supply disruptions if a primary supplier fails.

• Choosing Reliable Vendors: Work with ISO-certified manufacturers to ensure quality consistency.

• Local vs. Global Sourcing: Balance cost vs. lead times (e.g., sourcing PCB components locally but enclosures globally).

• Supplier Relationship Management: Negotiate long-term contracts for price locks and priority allocation.

Supply Chain Risks & Mitigation Strategies:

Risk	Solution
Component Shortages	Maintain a buffer stock for critical parts.
Geopolitical Uncertainty	Diversify suppliers across different regions.
Logistics Delays	Work with multiple shipping partners.
Quality Variability	Perform incoming quality inspections.

Example:

A company producing industrial sensors faced a semiconductor shortage and secured an alternate MCU supplier before production delays occurred.

4. Logistics and Production Planning

Efficient logistics and production scheduling minimize warehousing costs, lead times, and inventory risks.

Production Planning Strategies:

• Just-in-Time (JIT) Manufacturing: Producing only what is needed to avoid excess inventory.

• Batch vs. Continuous Production: Selecting the right model based on demand forecast.

• Pilot Runs Before Mass Production: Ensures early defect detection and process improvements.

Optimizing Logistics for Cost Efficiency:

• Bulk Shipping & Freight Consolidation – Reduces per-unit shipping costs.

• Localized Warehousing – Shortens delivery times for global markets.

• Smart Packaging Design – Reduces volume and weight to cut shipping costs.

Example:

A consumer electronics brand saved 15% on shipping costs by optimizing its packaging to fit more units per shipment without increasing weight.

Cost Optimization and Supply Chain Planning ensure that products remain affordable, scalable, and competitive. By applying smart BOM selection, efficient manufacturing techniques, and strategic sourcing, companies can maximize profitability while maintaining product quality.