Electronics development is a complex discipline that requires a combination of technical precision, deep know-how, and the ability to think in context. Behind every electronic device are hundreds or even thousands of components that must be properly arranged on a printed circuit board — similar to the construction of mechanical systems. Unlike mechanics, however, these components must also be correctly electrically interconnected.

Electromagnetic compatibility (EMC): an invisible but critical challenge

Electromagnetic properties — the physical behavior of a device in the real world — must also be taken into account. Electronics need to be designed so that they do not interfere with other devices nearby, do not disturb themselves, and remain resistant to external interference.

This is referred to as EMC (Electromagnetic Compatibility). It is the reason why you switch your phone to airplane mode on a flight, or why you may see signs at quarries prohibiting mobile phones and radios (because blasting is controlled electronically).

In practice, EMC is often underestimated, yet it is essential for the safe, reliable, and legal operation of electronic devices. Ignoring EMC principles can cause serious issues:

• Unreliable devices – unexplained errors, crashes, or unstable behavior caused by interference.

• Interference with other devices – unwanted signals disrupting nearby electronics.

• Failure to meet legal requirements – non-compliance with EMC directives (e.g., EMC Directive 2014/30/EU) can prevent market entry or lead to legal consequences.

• Higher costs for retrofits – if EMC isn’t addressed during design, fixing it later can be extremely difficult, expensive, or even impossible.

Harsh environments

Everyday human environments are actually very hostile to electronics — mainly due to humidity, temperature fluctuations, or electrostatic discharge (ESD). All of these factors can negatively affect the operation of electronic devices, which is why it is essential during development to account for them and design appropriate protective measures to ensure reliable performance under operating conditions. One example is the electrostatic charge generated by wearing a sweater, which can reach several thousand volts and discharge into a device when touched. Another is a temperature change that alters the parameters of electronic components.

Firmware for electronics

Most modern electronic devices include firmware — the software that controls them and enables more complex functions. It is necessary to carefully decide which functions should be implemented in software and which in hardware, taking into account the factors mentioned above as well as the costs of development and subsequent production. At the same time, practical aspects must be considered, such as the availability and lifecycle of the electronic components used.

Prototyping and simulation: the way to a functional product

Because electronics are complex and dynamic systems, an iterative development approach is essential — gradually creating and refining the design through prototyping. Not every version has to be physically manufactured; part of the development can be carried out through simulations, which make it possible to detect errors or optimize the design before production. This significantly shortens overall development time and reduces the costs of producing physical prototypes. On the other hand, professional circuit simulation software is a separate investment. In practice, several (typically 2 to 4) physical prototype iterations are still produced, as long as the overall device concept remains unchanged. Each of these versions serves to verify functionality, uncover weaknesses, and fine-tune the product toward the final version.

Testing: more than just switching it on

Testing electronics is usually more complex and time-consuming than testing purely mechanical products. Even if everything seems fine at first glance, subtle and hard-to-detect problems may occur: lights blinking differently than they should, failed communication between components, unstable firmware behavior, or external signal interference.

Testing often resembles detective work — developers spend hours with oscilloscopes or logic analyzers, searching for causes of issues that only appear under certain conditions, and continuously verifying what the real source of the problem is. Just as a detective never knows how long it will take to solve a case, a developer cannot precisely estimate how long it will take to remove all bugs and reach a stable, reliable state.

That’s why development timelines are always just estimates — and if a project is limited by a fixed budget, it is crucial to plan for sufficient time and financial reserves for debugging and testing.

Teamwork, not a one-man show

Since electronics development is such a complex and dynamic system, in most cases it cannot be reliably handled by just one or two people — it requires an experienced team of developers.

And if the development involves electronics subject to special regulations — for example in healthcare, automotive, aviation, or explosive environments — additional standards specific to the intended application must also be taken into account.

Summary: what must be addressed in electronics development

• Arrange hundreds or even thousands of components so that the final device meets the required dimensions and shape, remains compact, and is optimized for manufacturing.

• Design the electronics so that they do not emit unwanted electromagnetic signals that could interfere with other devices or themselves, while also ensuring resistance to external interference.

• Minimize adverse environmental effects and implement appropriate protective and stabilization measures.

• Carefully decide which functions should be implemented in hardware and which in software, taking into account technical requirements, development and production costs, reliability, and component availability.

• Conduct thorough testing and debugging of all functions with an emphasis on correct operation, long-term reliability, compliance with EMC requirements, and, where applicable, other industry-specific standards.