Getting a custom device developed sounds like a project for large corporations to many mid-sized businesses. In practice, the path from idea to working prototype is more structured than expected - once it is broken into traceable phases instead of treated as one big, opaque black box.
Phase 1: Requirements, not a wish list
It does not start with a finished spec sheet, it starts with a conversation: what problem should the device solve? Under what conditions will it run (environment, power supply, connectivity)? What quantities are realistic - a single unit, a small batch, or a production run? These questions already narrow down which components, which enclosure, and which manufacturing path even make sense.
Phase 2: Concept and feasibility
Before a single line of firmware gets written, technical feasibility comes first: which sensors, which microcontroller, which connectivity (Wi-Fi, LoRa, cellular, wired) fits the deployment location? This is often where it becomes clear that the original idea can be built faster and cheaper with standard components than expected - or that a requirement should be rethought before money flows in the wrong direction.
Phase 3: Prototype - the first working build
A prototype does not need to look good, it needs to work. This phase produces PCB layouts, a firmware skeleton, and a first mechanical build, often from 3D-printed or laser-cut parts. The goal is a device where the core function can be verifiably tested - not the finished production product.
Phase 4: Test, discard, improve
The first prototype rarely works perfectly, and that is normal. This is where you find out whether the sensors measure reliably under real conditions, whether power consumption fits the intended use, whether the enclosure holds up. Every iteration brings the device closer to production readiness - faster if you measure from the start instead of guessing.
Phase 5: Small-batch production
Once the prototype is solid, the jump happens from a one-off working unit to a reliable batch of ten or a hundred. That means component sourcing, manufacturing tolerances, a test procedure per unit, and a plan for what happens when a unit fails in the field. For smaller quantities, production in our own Think Tank lab at the Tegernsee often fits best - for larger runs we connect you with the right manufacturing partners.
From hardware to a connected device
Many hardware projects do not end at the enclosure - that is where they really begin. A device that collects data is only as useful as the software behind it. Wallboards, control panels, terminals, or access devices - our IoT experience covers the full chain from sensor through firmware to cloud connectivity.
Frequently asked questions
How long does development take from concept to prototype?
Depending on complexity, anywhere from a few weeks for a simple sensor device to several months for a complex connected system with a custom enclosure.
Do we need a finished technical specification already?
No. The feasibility phase works out the technical details together - at the start, describing the problem and the constraints is enough.
Can very small quantities be produced?
Yes. Single units and small batches can be produced in our own lab - often the fastest path for prototypes and pilot projects.
You have an idea for a device but do not know where to start? Let us talk about it in a first conversation, or read more about our custom hardware development and our IoT solutions.