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How to Improve Product Longevity in Electronics Manufacturing

How to Improve Product Longevity in Electronics Manufacturing

August 8th, 2024

We’ve all experienced the heartbreak of a beloved gadget giving up the ghost way too soon. In the case of mobile phones, some even say they feel like their entire life is gone. It’s no wonder, knowing that we live in the digital world and everything important is in the database of a gadget. Just remember what we do on our mobile phones: we have access to social media, mobile banking, email accounts, contacts of people we claim are important to us. Sometimes there is work there too. And when the phone brakes, everything stops.

Did you know that the estimated lifespan of a mobile phone is 6 years and laptops only 4? Still, we all witnessed that sometimes, as soon as the warranty expires, you’re free to buy a new gadget. For smartphones that usually means only 2 years.

However, engineers and manufacturers are doing their best to prolong the lifespans of gadgets.

Why it matters

For customers, durable products mean fewer replacements and repairs, saving both money and the environment. For manufacturers, it builds a solid reputation, reduces returns, and fosters customer loyalty. Plus, who doesn’t want to be known as the Gandalf of electronics, wielding gadgets that stand the test of time?

Choosing the right materials

Every journey begins with the foundation, and in our case–materials. Just like a chef selects the finest ingredients to whip up a culinary masterpiece, manufacturers must choose top-notch materials for their products.

Let’s take printed circuit boards (PCBs), for example. They are essential for every modern gadget, and the longevity of one device can be linked to the longevity of one’s PCB. That’s why manufacturers are working on new PCB conformal coating types that will prolong the life of a PCB. What does that mean in the long run? PCBs are part of devices that often need to work under pressure or high temperature, and it’s important to get them protected. Adding coating on PCBs means adding extra protection. And naturally, it’s all about choosing the proper materials for coating.

Some materials are cheaper than others. Some are high-quality but they’re more costly. It’s all about the balance between the need and the budget. But skimping on components is like using margarine instead of butter in a cookie recipe–sure, it’s cheaper, but the results are disappointing. Manufacturers should try to invest in high-quality resistors, capacitors, and other components. That will give gadgets better durability.

The outer shell protects the delicate innards of your gadget. You can opt for stainless steel, and if that proves to be heavy, you can try some other materials like polycarbonates or aluminum. Think of it as armor for your electronics. Speaking of such, do you remember those first Nokia mobile phones? They were truly Chuck Norris among phones. Their reputation for unbreakable gadgets will never cease.

Electronics generate heat, and heat is the enemy of longevity. That’s why it’s important to use materials that can withstand the heat. FOr instance, silicone is great at high temperatures, but it’s costly.

When talking about meltdowns, it’s important that your gadgets are water resistant or even chemical resistant. Why? Just think about all the accidents that can happen in the bathroom or kitchen. Or you can simply get wet in the rain. For example, silicone is moisture resistant, urethane is moisture and chemical resistant, and epoxy is chemically resistant.

The choice of materials really depends on the conditions you’ll be using them in. For instance, outdoor surveillance cameras, mobile phones, and submarine navigational systems might all have different materials due to different needs.

Design with longevity in mind

Now that we have our materials sorted, let’s see how design can influence longevity. A well-thought-out design is like a well-tailored suit–it fits perfectly and lasts longer.

Manufacturers are trying to keep the design simple and avoid unnecessary complications. Fewer parts mean fewer chances of something going wrong. Plus, simplicity is elegant and timeless.

Modular design looks like a lego set. It’s built in such a way that individual components can be easily replaced or unplugged. This not only extends the product’s life but also makes repairs a breeze.

Remember the heat we talked about earlier? Manufacturers can incorporate effective thermal management solutions like heat sinks, fans, and thermal pads to keep your device cool as a cucumber.

Electronics don’t enjoy being jostled around. Many have designs for shock and vibration resistance, especially if the product is meant to be used on the go. There are rubber mounts, gaskets, and other dampening materials to cushion the impact.

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Testing, testing, 1-2-3

Every product needs to go through testing. Manufacturers need to be sure the product can take the road ahead.

In stress testing, they push products to its limits. They expose it to extreme temperatures, humidity, and electrical stress. That way potential weaknesses can be detected. If it survives, it’s ready for anything!

How do manufacturers predict the lifespan of a device? They simulate the product’s lifespan by running continuous operation tests. This also helps identify wear and tear issues that may not be immediately apparent.

Also, it’s wise to test products in different environmental conditions like dust, moisture, and altitude. It’s like sending your gadget on a world tour to see how it handles the journey.

Finally, real users get to test the product in real-world conditions. User feedback is invaluable and can highlight issues that lab tests might miss.

Manufacturing and the assembly line

You’ve got the materials, the design, and the testing down parts. Now it’s time to bring it all together on the assembly line. Manufacturing excellence is important for product longevity.

So, manufacturers need to implement rigorous quality control measures at every stage of production. That’s important because catching defects early prevents faulty products from reaching the market.

Employees at production should also be skilled, whether they come like that or they got training about what is best for the company’s needs. Skilled technicians are less likely to make mistakes that could compromise product longevity.

Naturally, equipment should be state-of-the-art. Nobody can expect prime products to be created with equipment from the past century. Robots, automation, and CNC machines can significantly improve the quality of products.

Also, manufacturers need to keep a clean and controlled manufacturing environment. Dust and contaminants can wreak havoc on delicate electronic components.

After-sales support

The product’s journey wouldn’t be complete without addressing after-sales support. Even the most durable products might need a little TLC from time to time. When manufacturers offer excellent after-sales support, it’s like providing a safety net for the customers.

That could be done through giving comprehensive warranties and hassle-free repair services. The more generous warranty–the more confidence manufacturers have of their product’s longevity.

Have you ever found yourself choosing one product among many others just because spare parts were more available? People usually do that when buying cars, but the same could be applied to laptops too. That’s why it’s great when manufacturers provide readily available spare parts. When repairing, you’re not replacing the product, thus it lasts longer.

As potential customers, we need to be educated on proper care and maintenance. Simple tips like keeping devices clean and avoiding overcharging can go a long way in prolonging their lifespan. Those tips can usually be found next to the product, in the same package. If not, you can probably find something on the manufacturer’s website.

There should also be recycling programs so that you can responsibly dispose of old and damaged products. This shows the brand’s commitment to sustainability along with benefits it has on the environment. Many people are choosing products based on how they impact the environment.

Innovation and future proofing

Manufacturers need to keep an eye on emerging trends and technologies. They can try to incorporate the latest advancements into their designs to keep products cutting-edge.

To keep products fresh and functional, they should have regular updates to fix bugs, improve performance, and add new features.

Materials should be eco-friendly to reduce waste and minimize carbon footprint. Sustainable products are not only good for the planet but also appeal to environmentally-conscious consumers.

If you have any feedback on the product, feel free to share it. Many manufacturers continuously gather and analyze customer feedback, since this can lead to innovation and understanding the consumer’s needs.

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A new beginning

The quest for longevity is an ongoing journey. Manufacturers are embracing innovations, listening to their customers, and always striving for improvement. Who knows? Their next creation might just be the stuff of legends, outlasting even the oldest electronics in the hall of fame (like that Nokia mobile phone).

So let’s all go forth and may our products live long and prosper!

The author:

Petra Rapaić is a B2B SaaS Content Writer. Her work appeared in the likes of Cm-alliance.com, Fundz.net, and Gfxmaker.com. On her free days she likes to write and read fantasy.