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Predictable Designs Podcast

John Teel, a former Texas Instruments chip designer, for hardware startups and entrepreneurs bringing a new electronic product to market: developing, manufacturing, marketing and selling it.

48 episodes · 31 hours · since 2020

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Predictable Designs Podcast has ended.

Its last episode came out on 25 Jan 2023. The whole back catalogue is still here to explore, every episode with its summary and chapters.

Predictable Designs Podcast is filed under electronics, product development and startups. Its most recent episode published on , so it sits in the archive rather than the active listings. Listeners have left 12 ratings on Apple Podcasts, averaging 5 out of 5.

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Where to begin with Predictable Designs Podcast: full episodes about building physical products, award winners first.

  • · 1h 05m

    3D Printing and Additive Manufacturing with Steve Szymeczek of Penumbra Engineering

    Steve Szymeczek of Penumbra Engineering explains the practical applications of additive manufacturing for low-to-medium volume production, contrasting it with traditional injection molding. He details the cost-effectiveness of technologies like FDM and HP Multi-Jet Fusion for startups needing 100 to 10,000 units, emphasizing the importance of designing for injection molding even when using 3D printing for prototyping. Szymeczek also discusses the benefits of distributed manufacturing, material limitations, and the role of generative design in creating complex, value-added parts.

    Prototyping & iterationMaterials & manufacturing processes
    7 chapters

  • · 1h 01m

    PCB Assembly and Design for Manufacturing with Duane Benson of Screaming Circuits

    Duane Benson, Director of Marketing at Screaming Circuits, explains the PCB assembly process, contrasting their prototype/small-volume model with parent company Milwaukee Electronics' high-volume contract manufacturing. He details the workflow from programming and solder paste deposition to reflow, inspection, and rework, while highlighting common Design for Manufacturing (DFM) pitfalls like open vias and incorrect QFN footprints. The discussion covers the infeasibility of home PCB prototyping, the cost-benefits of US-based assembly, and critical tips for ensuring component availability and accurate footprints.

    PCB design & layoutManufacturing partners & offshoring
    10 chapters

  • · 1h 01m

    How to Evaluate Suppliers and Manufacturers with Mike Morena and Shawn Litingtun

    Host John Teel speaks with Mike Morena, founder of AdhereTech, and electronics consultant Shawn Litingtun about evaluating suppliers and manufacturers for hardware startups. They discuss specific criteria for assessing electronics manufacturers, such as the number of SMT lines and automated optical inspection capabilities, and plastics manufacturers, focusing on in-house tooling and DFM reviews. The guests emphasize the importance of factory visits, ISO certification, and robust traceability systems to mitigate risk and ensure quality.

    Manufacturing partners & offshoringQuality & yield
    7 chapters

Hear it in a few minutes

Single discussions from recent episodes, playing the show's own audio from where each begins.

Latest episodes

  • · 43m

    Q&A - Best PCB Design Software, Finding Co-founders, and Avoiding Unsold Inventory

    Host John Teel answers questions from his Hardware Academy members regarding PCB design software, sales strategy, and co-founder selection. He advises entrepreneurs to use accessible tools like KiCad or DipTrace rather than expensive suites like Altium or Eagle, warning that software incompatibility can hinder future outsourcing. To avoid unsold inventory, he recommends pre-selling to a warm audience and starting with small production runs to validate demand before scaling. Finally, he suggests finding a technical co-founder through networking and universities, emphasizing that the founder must demonstrate significant progress and risk-taking to attract serious partners and fair equity splits.

    PCB design & layoutDirect-to-consumer & e-commerce
    1 chapters

  • · 17m

    The Ugly Truth About Prototyping a New Product

    Host John Teel explains the iterative stages of prototyping electronic hardware, emphasizing that no single prototype suffices for mass production. He details the progression from low-cost Proof of Concept (POC) prototypes using development kits like Arduino or Raspberry Pi to 'looks-like' models made of clay or 3D printed, and 'works-like' prototypes with custom PCBs. Teel outlines the critical transition to pre-production prototypes optimized for injection molding, followed by Engineering Validation Testing (EVT), Design Validation Testing (DVT) for certifications like FCC and UL, and Production Validation Testing (PVT) for pilot runs.

    Prototyping & iterationPCB design & layout
    6 chapters

  • · 18m

    Microcontroller Showdown: Selecting the Best One for Your Project

    Host John Teel explains how to select the right microcontroller for electronic products, warning against mid-project changes and emphasizing the need for 'room to grow' in GPIO and performance. He categorizes microcontrollers into 8-bit, 16-bit, and 32-bit families, detailing specific architectures like the 8051, PIC, AVR, MSP430, STM32, and ESP32. Teel compares their costs, peripherals, and development ecosystems, noting that 32-bit chips like the STM32 and ESP32 have become cost-competitive with 8-bit options while offering superior features.

    Microcontrollers & dev platforms
    1 chapters

  • · 8m

    How Long Does It Take to Develop a New Electronic Product?

    John Teel, host of the Predictable Designs podcast, explains that the time to develop an electronic product depends on three critical variables: product complexity, the founder's involvement, and budget. He illustrates how unnecessary features like wireless charging can triple development time and cost, advising entrepreneurs to simplify designs. Teel shares his personal experience of learning 3D modeling to avoid delays caused by external engineers, emphasizing that no one works harder than a focused founder. He concludes with concrete estimates, suggesting 3-6 months for a first prototype and 9-12 months for a final version if expertise exists, plus additional time for certification.

    Validation & product-market fitPrototyping & iteration
    1 chapters

  • · 19m

    How to Outsource Product Development

    Host John Teel explains how to outsource electronic product development by balancing experience, cost, location, and trust. He advises hiring specialized engineers with relevant product experience, using independent design reviews to mitigate risk, and paying via fixed-price milestones to control budget. Teel also distinguishes between proof-of-concept prototypes using off-the-shelf modules and manufacturable custom PCB designs, warning against switching software like Altium or Eagle mid-project.

    Manufacturing partners & offshoringPricing, margins & unit economics
    6 chapters

  • · 18m

    Microcontroller or Microprocessor - Which Do You Need for Your Project?

    John Teel, host of the Predictable Designs Podcast, explains how to choose between a microcontroller (MCU) and a microprocessor (MPU) for electronic products. He argues that 90% of projects should start with an MCU, citing the STM32F469 as a high-performance example that bridges the gap for displays. Specific use cases like 1080p video, USB 3.0, and complex GUIs require an MPU, while battery life and simple control favor an MCU. Teel also contrasts development platforms like Arduino and Raspberry Pi to guide prototype-to-production decisions.

    Microcontrollers & dev platformsPCB design & layout
    1 chapters

  • · 20m

    The Costs to Develop & Manufacture a New Electronic Product

    Host John Teel breaks down the three major cost categories for developing and manufacturing electronic products: development, scaling, and landed production. He details specific expenses including electronics, software, enclosure prototyping, and retail packaging design, emphasizing that entrepreneurs often underestimate these initial outlays. The discussion then shifts to scaling costs, highlighting certification fees and the significant expense of injection molds required for mass production. Finally, Teel analyzes landed production costs, covering components, PCB assembly, labor, testing, scrap rates, packaging, freight, and duties, warning that ignoring these figures leads to financial failure.

    Pricing, margins & unit economicsDesign for manufacturing & NPI
    1 chapters

  • · 20m

    15 Steps to Develop a New Electronic Hardware Product

    Host John Teel outlines a 15-step framework for developing new electronic hardware products, emphasizing the critical importance of early cost estimation and manufacturing feasibility. He details the progression from product definition and preliminary design to schematic capture, PCB layout, firmware development, and enclosure prototyping via 3D printing. The process concludes with iterative testing, debugging, and obtaining necessary electrical certifications like FCC and CE before mass production.

    PCB design & layoutPrototyping & iteration
    9 chapters

  • · 14m

    13 Reasons Why New Hardware Products Fail

    Host John Teal outlines 13 common reasons why new hardware products fail, categorized into technical, financial, and sales/marketing challenges. He emphasizes critical pitfalls such as underestimating development time, neglecting design for manufacturing (DFM), and running out of cash flow due to inventory costs. Teal also highlights the importance of validating customer demand early through crowdfunding and building an audience before launch.

    Design for manufacturing & NPIPricing, margins & unit economics
    1 chapters

Every episode

48 episodes with a summary and chapters, by year.

20233 episodes
  1. 25 JanQ&A - Best PCB Design Software, Finding Co-founders, and Avoiding Unsold Inventory43m
  2. 11 JanThe Ugly Truth About Prototyping a New Product17m
  3. 4 JanMicrocontroller Showdown: Selecting the Best One for Your Project18m
202213 episodes
  1. 28 DecHow Long Does It Take to Develop a New Electronic Product?8m
  2. 21 DecHow to Outsource Product Development19m
  3. 14 DecMicrocontroller or Microprocessor - Which Do You Need for Your Project?18m
  4. 7 DecThe Costs to Develop & Manufacture a New Electronic Product20m
  5. 30 Nov15 Steps to Develop a New Electronic Hardware Product20m
  6. 23 Nov13 Reasons Why New Hardware Products Fail14m
  7. 9 NovWORST DAY Bringing a New Product to Market11m
  8. 19 JulWhy You Must Simplify Your Product to Succeed10m
  9. 12 JulWhy Patents Are a Death Trap for Entrepreneurs!12m
  10. 5 JulTop 10 Product Design Mistakes You Must Avoid16m
  11. 28 JunHow to Know If Your New Product Idea is a Good One to Pursue18m
  12. 21 JunHardware Entrepreneurs: 3 Critical Mistakes You Must Avoid9m
  13. 14 AprHow to Validate the Market for Your New Product with Ivo Kalburdzhiev of CreatorClub54m
20214 episodes
  1. 2 JunHow to Build an Audience for Your Product with Craig Rettew54m
  2. 18 MayProduct Simplification, Marketing, and Crowdfunding with Miguel Hernandez of Palocam43m
  3. 27 AprHow to Execute Quickly with Miguel Hernandez of Palocam1h 03m
  4. 21 AprQ&A with Miguel Hernandez, Creator of the PaloCam47m
202028 episodes
  1. 31 AugMarketing Lessons Learned with Fraser Vaage, Founder of Snik1h 02m
  2. 24 AugThe Importance of Defining Project Milestones with Dave Millman of SalesDev.Global53m
  3. 21 JulHow to Define and Specify Your New Hardware Product24m
  4. 13 JulHow to Validate Your Product Idea Before You Spend Serious Money On It36m
  5. 6 JulSupply Chains and Manufacturing with Charles Lin of TechDesign51m
  6. 29 JunFrom Corporate World to Freelancing to Running a Hardware Startup with Roberto Weiser of Developpa53m
  7. 22 JunHard Earned Lessons Learned with Wayne Frick of ChirpSounds – Part 240m
  8. 11 JunHard Earned Lessons Learned with Wayne Frick of ChirpSounds - Part 138m
  9. 6 Jun6 Facts About Product Development That Hardware Startups Underestimate with Dave Millman of SalesDev.Global49m
  10. 15 MayImportance of Technical Advisors and Product Simplification23m
  11. 7 MayDevelopment Costs for Hardware Startups27m
  12. 4 May6 Strategies to Get Your Product Developed25m
  13. 27 AprQuestions on Outsourcing, Distribution Channels, and the Cost to Market33m
  14. 10 AprHow to Evaluate Suppliers and Manufacturers with Mike Morena and Shawn Litingtun1h 01m
  15. 2 Apr3D Printing and Additive Manufacturing with Steve Szymeczek of Penumbra Engineering1h 05m
  16. 24 MarSucceeding in Hardware with Joshua Hsu of Introhm1h 03m
  17. 23 MarHardware Startup Horror Stories and How to Avoid Them with Dave Millman of BizDev.Global46m
  18. 12 MarTransition from Prototype to Mass Manufacturing with Scott Miller of Dragon Innovation1h 05m
  19. 3 MarPCB Assembly and Design for Manufacturing with Duane Benson of Screaming Circuits1h 01m
  20. 1 MarBusiness of Startups with Marty Zwilling of Startup Professionals53m
  21. 18 FebConcept to Market in One Year with Allen Walton of SpyGuy.com [Part 2]47m
  22. 17 FebConcept to Market in One Year with Allen Walton of SpyGuy.com [Part 1]1h 02m
  23. 2 FebProduct Design and Manufacturing with Nick Frank of Knectiv46m
  24. 27 JanFrom Crowdfunding to Development and Manufacturing with Erik Hunter of InD Creation49m
  25. 19 JanThe Advantages and Challenges of Manufacturing in China with Case Engelen of Titoma49m
  26. 7 JanFive Biggest Mistakes Hardware Startups Make with Customers with Dave Millman of BizDev Global38m
  27. 7 JanHardware Development with No Prior Experience with Kris Christopher of Grow Nanny43m
  28. 6 JanThe Journey from Idea to Success with Mike Morena of AdhereTech37m

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