FROM THE IDEA TO THE SERIES: ELECTRONIC SOLUTIONS AT BAUDISCH

At Baudisch Electronic, we support our customers from the initial idea to the finished series product and beyond. Our claim: reliable, standard-compliant and high-quality electronic solutions.

DEVELOPMENT: FROM CONCEPT TO FUNCTIONAL PROTOTYPE

The development phase forms the basis for every electronic product.
It is crucial for ensuring that subsequent production and quality assurance function smoothly.

Based on the product idea, requirements are analyzed and transferred into an overall technical concept. This includes circuit development, PCB layout and – depending on the application – the development of software or firmware.

Even during development, attention is paid to production-ready design, component availability, testability and EMC-compliant design. Another important component is cyber security, so that software and firmware minimize potential points of attack, protect sensitive data and meet relevant security standards.

The result is a functional, safe prototype that serves as the basis for the pilot series and subsequent series production.

PROTOTYPES: VALIDATION OF FUNCTION AND DESIGN

Functional prototypes are produced on the basis of the developed concept. These are used to verify the circuit, software, layout and the interaction of all components under realistic conditions.

In the prototype phase, the focus is on function, performance and safety. Findings from measurements, tests and commissioning are specifically incorporated into design optimizations.

Only when functionality and design are stable is the product released for transfer to pilot production.

EMV TESTING: PRODUCT DESIGN ACCORDING TO STANDARDS

EMC-relevant aspects are already taken into account during development, e.g. layout design, shielding, filter concepts and the selection of low-interference components.

As part of the test, interference emissions and immunity are measured in accordance with the relevant standards, both conducted and radiated. The results are used to optimize the circuit, circuit board layout and housing design so that the product is prepared for series production in accordance with the standards without unnecessary additional costs.

ZERO SERIES: TRANSITION FROM DEVELOPMENT TO PRODUCTION

Once the prototype phase is complete, a pilot series is produced to validate the approved product design under real series conditions. The focus is no longer on functional changes, but on validating production processes, assembly, test concepts and documentation.

The pilot series serves to ensure the reproducibility, process stability and quality of the electronic assemblies. Findings from this phase are specifically incorporated into the optimization of production processes, testing strategies and logistical processes.

The transition from pilot series to series production takes place as part of the established NPI process. This ensures that the product is stable both technically and in terms of the process and meets all relevant requirements.

PURCHASING: COMPONENT AVAILABILITY AND SECURITY OF SUPPLY

Strategic purchasing plays a decisive role in parallel to the preparation of series production. Even before the start of series production, components are evaluated in terms of availability, service life, alternatives and cost structure.

Early coordination between development, purchasing and production minimizes risks such as delivery bottlenecks or discontinuations.

SERIES PRODUCTION: STABLE PROCESSES AND CONSISTENT QUALITY

Once the pilot series has been successfully produced and EMC testing has been completed, series production begins. In this phase, quality-assured, product-specific defined processes are used to ensure consistently high product quality.

Depending on the product requirements, PCBs are assembled using SMD, THT or combined technologies. Not every assembly requires all production steps – the scope and process are consistently based on the design, function and application. If necessary, assembly work is also carried out right through to the tested end device.

Regardless of the scope of production, each assembly undergoes defined optical, electrical and functional tests to ensure compliance with the specifications. Documented testing and approval processes guarantee reproducibility and quality throughout the entire series production period.

The close integration of development, production, purchasing and EMC testing also makes it possible to implement customer-specific changes or standard adaptations efficiently and in a controlled manner without compromising the stability of series processes.

LIFECYCLE MANAGEMENT: PRODUCT SUPPORT BEYOND THE SERIES

Even after the start of series production, the product life cycle does not end. As part of lifecycle management, we support electronic products throughout their entire service life. This includes obsolescence management, component changes, redesigns and adaptation to new standards or market requirements.

In this way, we ensure that products remain available, maintainable and technically up-to-date in the long term – even when conditions change.

The process from the idea to series production shows how important continuous EMS-supported development is. The combination of structured development processes, pilot series, EMC testing and stable series production results in reproducible, standard-compliant and safe electronic products.

This approach forms the basis for high-quality electronic solutions that are implemented reliably, efficiently and in compliance with standards.