Make it simple
Founders, it sounds counterintuitive, but hear me out. In wearables, every fraction of a millimeter matters. You fight to reduce the size of the logic board by every 0.1 mm. You search for low-profile components. And you are tempted to make complex multi-layer PCBs.
Except you should not. Make it simple.
A multi-layer, flexible PCB with blind vias makes the life of the PCB designer easier. A lot easier. Sometimes you can double the development speed by using these complex technologies.
But the convenience always comes at a cost. 4-6-8-layer PCBs are more expensive and take longer to make. Blind vias can easily double the cost and limit your choice of suppliers significantly. Most prototyping companies just don’t make PCBs with blind vias. Flexible PCBs make the cost skyrocket and lead times go towards infinity. And tank production yields.
BGA ICs require better SMT machinery and more skilled personnel. X-ray inspections are no longer optional.
I can continue this list on and on, but here’s the point: the more complex tech you’re using, the more expensive it gets, and the longer your iterations become.
In startups, everything is about cost and speed. You need to iterate as fast as you can, and you need to make it as cheap as you possibly can.
Complex PCBs are some of the most time-consuming and cost-increasing components. So stick with simple, preferably 2-layer rigid PCBs, machine-installed connectors, and bulkier, but simpler ICs whenever possible.
Even if your engineers say it’s impossible, push. Eventually, they will find a way to reroute lanes and reposition components. And then, each iteration of prototyping and mass production becomes weeks shorter. And way cheaper.
Ask your engineers to prioritize simplicity and costs. Make them focus on it. Trust in your team, they can do it. Just be clear on that: make it simple.
If your engineering team says "it’s impossible" but your burn rate says "it’s necessary", let’s talk. I help fix unit economics in hardware startups. Book a free Leak Check.
