Product Design Mockup and Prototypes

• The product with the PCbs, transformer and other panel components should fit in the box it was intended for, or the cabinet that was designed for the Product. To make sure make a Mock-up Product - 3D and display. Even if you have all documents and drawings in place.
• Make sure of IC pin numbers, size and packages and indicate in circuit like 40 pin dip before going to PCB. Also check every EDA symbol in your software with the company datasheet to make double sure.
• Whatever be the specs, design or simulation nothing like a prototype being tested by the customer in his environment. So do not go into volume production till such a test is done.
• You need a Fuse, Circuit breaker and earth leakage circuit breaker for safety against shock and fire hazard.
• A thermistor must be used in series with huge power electrolytic capacitors to limit the enormous current inrush on start, or spikes may stress components, cap or EMI-RFI.
• Sometimes a component can be defective, may not be what it is labeled or may be of a wrong value. In manufacturing 100% incoming inspection of components can catch these errors, Before Assembly of prototypes just test all passive and active components with a DMM and put all ICs in bases, then troubleshooting is easy.
• SMPS designs should have clear line or patch of isolation for product safety and long term reliability. If you use opto-couplers they need to have 5kV or better isolation and 10mm between pins. The Live circuitry and the output circuitry should not overlap on PCB, tracks should not stray to the opposite side, The Transformers can be split bobbin if possible. A 10 to 20 mm desert (means no tracks) running from end to end of PCB under Transformer and under optos etc., Even ground tracks and ground planes should not stray.

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