Electronics manufacturing is full of risks, but some of the worst ones come from mistaken beliefs. These myths can derail timelines, inflate costs, and even kill products before they reach the market. In this article, we break down three of the most dangerous misconceptions—and what you should understand instead.
Myth 1: You Can Fix Issues Later
The Reality:
Once tooling begins, changes are expensive, time-consuming, and often messy. Unlike software, you can’t push a quick update when the product is already in plastic or metal.
The Fix:
Design for Manufacturing (DFM) must come into play as early as possible. This means collaborating with your manufacturing partner while still shaping the design, so that considerations like part availability, assembly procedures, and test methods all factor into each decision. Early prototypes and thorough reviews can reveal problems lurking beneath the surface—saving you significant rework down the road. Staying vigilant about tolerances, mating parts, and process constraints will help you avoid costly retooling after mass production starts.
For more on DFM principles, check out our complete DFM electronics guide.
Myth 2: Any Factory Can Build My Product
The Reality:
Not all factories are equal. A factory that does great work on toys might fail miserably on an IoT device with tight tolerances and wireless certification.
The Fix:
Rather than focusing solely on price, prioritize a factory’s prior experience with products similar to yours. Evaluate how their processes and quality systems align with the complexity of your design—especially in areas like antenna tuning or tight-fitting enclosures. On-site audits can help you judge their capability, equipment, and responsiveness. Engage directly with their engineering and production teams to gauge their technical knowledge and approach to problem-solving.
As the Wall Street Journal puts it, “Finding a supplier is only the beginning” You also need to know how they handle problems under pressure. You can learn more about finding the right ODM in Taiwan or China.
Myth 3: BOM Costs = Total Product Cost
The Reality:
Looking only at the Bill of Materials is misleading. That number doesn’t include yield loss, testing time, packaging, shipping, tariffs, or rework.
The Fix:
Understand that a low BOM can hide higher failure rates and additional downstream costs like logistics, quality control, and tariffs. To accurately project your total spend, calculate what’s often called the “True Landed Cost.” This means including everything from production yields and compliance certifications to packaging materials and freight charges. Factoring in these details early helps you avoid sticker shock later and prevents small hidden costs from adding up into a large financial burden.
What This Means for You
Believing these myths can turn a promising product into an expensive headache. The good news? If you plan carefully, involve manufacturers early, and take a holistic view of cost and capability, you can avoid most of these traps.
At Titoma, we help companies design and manufacture custom electronics from concept to mass production, with a focus on avoiding these very pitfalls.
