For product designers, 2021 was a year of supply chain nightmares. Many electronic parts suppliers were completely unable to keep up with demand, leading to significant shortages of multiple components—not just microchips as many news outlets have been quick to report.
While these supply chain issues may gradually correct themselves over the next few months or years, as product designers, we don’t exactly have the luxury of sitting around and waiting. We NEED to get our clients’ products into the marketplace as soon as possible!
At Kablooe, we’re assisting many of our clients in getting their products to market despite these severe—and often unpredictable—electronic part shortages. It hasn’t been easy, though. Fortunately, I’ve learned a lot from my colleague Mitch Maiman at IPS (who wrote this excellent article on his company’s approach to the same supply chain shortages).
This guide is my attempt to cover a variety of strategies for how Kablooe has best seen success when designing new products around these supply chain restraints. I sincerely hope they’ll work for you as well.
1. SUBSTITUTE SECONDARY COMPONENTS INTO YOUR DESIGN
In some cases, it may be possible to substitute secondary components for those that are in short supply. This could help to reduce the number of components that are needed, making it easier to find replacements if necessary.
In these situations, it’s critical that you only seek components that are compatible with your current firmware. Make sure your engineering team pays close attention to the drivers, as some will allow for subtle variations while others will not.
2. IMPLEMENT A DUAL FOOTPRINT DESIGN
Another option is to use a dual footprint layout in your design. This involves designing products that use two different footprints for electronic components, giving product designers more options when it comes to finding replacement parts. This is particularly true for alternative package modifications of the same microchip from a single vendor source.
3. UPGRADE TO NEXT-GENERATION COMPONENTS
Not every product is fully compatible with the newest generation of microchips. If you’re using an older design from your supplier, there’s a good chance those components will be nearing obsolescence. Of course, you can typically do a last-time purchase, but that is only ever a temporary solution.
Many suppliers are already starting to stock next-generation components, so this is as good a time as any to check on their product inventories. If possible, upgrading to these newer components can help to avoid potential shortages in the future, or at least until the majority of manufacturers adopt.
4. USE AN AUXILIARY MICRO CARRIER CARD
One unique way to work around component shortages is to design using an auxiliary microcarrier card (or two). This card would house smaller components that would normally be placed on the motherboard, freeing up necessary space and making it easier to find replacement parts if needed. This approach is nice because it allows you to change course as needed.
The carrier card might also help you avoid issues related to obtaining the same component in several package versions. Using a previously produced circuit board may provide an edge because it has already passed EMC testing and other regulatory approval procedures.
5. REPURPOSE PARTS FROM EVALUATION BOARDS
Occasionally, we may require specific components for use in low-volume or early-stage production, and getting them in the open market can be especially difficult (if not impossible). Fortunately, we have acquired many evaluation boards over the years with the exact chipsets we need or found new ones we could purchase at cost.
In the most time-sensitive and critical situations, we have harvested the parts we need off those boards and used them in the final product. This can be a risky move, though, as it may be difficult to find replacement parts should something go wrong. With that said, it can be a great way to get your product to market quickly when you have no better options.
FINAL THOUGHTS ON DESIGNING PRODUCTS AMIDST AN ELECTRONICS SHORTAGE
While these tips can help product designers work around severe electronics shortages, it is important to remember that no one knows for sure how long the current supply chain issues will last. It’s certainly possible that they’ll continue indefinitely, so as product designers, we should be prepared for this likelihood.
If you require further assistance, please contact the product design experts at Kablooe. We’re assisting many businesses in navigating these turbulent supply chain waters, and we’re happy to do the same for you.