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Geek Culture / Custom Electronics Production Costs

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Dark Java Dude 64
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Posted: 17th Mar 2011 02:41 Edited at: 17th Mar 2011 23:38
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So this post is to complement my other Gaming Console post that is here. What would be the cost of getting something like this manufactured? Here is my plan, as i only want to make one prototype to mess and experiment with. I will have a plastics company make a plastic housing that i designed. Ill get a PCB i designed printed by another, i could even do it myself The i would finally just order a bunch of parts from another company, things like chips, FPGA's etc. How much would this all cost if the console were to consist of a simple complexity and thus few parts, that similar to an NES? Again im only making one and assembling it myself. Also, any suggestions when it comes to getting parts a bit cheaper? I wont be using a custom chip, i will likely use an FPGA, if that's any good for an actual microprocessor... If anyone knows of a cheap way to make an injection mold then tell me please! Lol those prices surprised me...

I appreciate all helpful replies. Thanks!

Debugging is twice as hard as writing the code in the first place. Therefore, if you write the code as cleverly as possible, you are, by definition, not smart enough to debug it.
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The Wilderbeast
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Posted: 17th Mar 2011 17:13
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Well it all depends on how complex you make the design. With the housing it's not the materials / plastics that cost the most, it's the design of the mold itself.

Producing PCBs in-house is only suitable for prototyping, if you want commercial standard, multi-layer PCBs then it is something you will have to get a third party to do.


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Van B
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Posted: 17th Mar 2011 17:29
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To get a semiconductor chip manufactured.... well it's not even worth guessing here, because there are very few avenues. In fact it takes a lot of work and money to prototype a chip, because silicon is expensive, the process is expensive, and that expense can only be justified by sales. We get grants here for helping students develop their chips, but it's all PHD students. Beyond that, you are screwed. Unless you happen to have a spare £60,000 for a semiconuctor development, for a chip that might then go in a power supply, or act as a sensor or timer. It's an expensive business - for a hobbyist making their own console, well it's just not practical, even the humble NES has a lot going on under the hood.

There are PIC systems, hell there's even PIC basic, but the technology involved in making anything more complex than a ZX81 is insanely complex. You can get plans for a ZX81 to make yourself, maybe starting with that would be an idea, expand on it if you can.

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Plystire
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Posted: 17th Mar 2011 18:03
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For prototyping purposes, it would be unwise to go the SCC route. Instead of having a chip manufactured, just make the circuit that the chip is designed to replace. The console itself will be much larger, but you will be saving tons of money!

Many manufacturing companies do not cater to hobbyists and you generally would only turn to a company for manufacturing if you're going to buy in bulk. This applies not only to the PCBs, SCCs, but to the case housing as well.


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Code eater
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Posted: 17th Mar 2011 19:37
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If your going to make the case you will most likely want to get it injection moulded. The only expensive bit of which is creating the steel mould which will set you back up to around £50,000. So with a chip and case this is gettin a pretty expensive hobby

If pots and pans were "if"s and "and"s there would be no work for programmer's hands...
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bitJericho
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Posted: 17th Mar 2011 21:55
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If you can get access to a 3d printer, that might aid in prototyping.

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DeadTomGC
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Posted: 17th Mar 2011 23:14
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I would say screw the case, at least for the prototype. Just add structure and fans or what ever else you need as you go.

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Dark Java Dude 64
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Posted: 17th Mar 2011 23:36 Edited at: 17th Mar 2011 23:53
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Well i originally had no plans of getting a custom chip made, those prices are darn scary... And yeh, i thought the case would be the cheapest part, but upon doing some research last night i might just have to screw the case!


So then how much would it cost to make a sweet metal case like that of an iPod Shuffle or Nano? I bet that has some extreme cost setback as well. It seems like everything custom is cheap to make in and of itself, but the custom things required to make it are what is expensive...

Debugging is twice as hard as writing the code in the first place. Therefore, if you write the code as cleverly as possible, you are, by definition, not smart enough to debug it.
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Interplanetary Funk
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Posted: 18th Mar 2011 00:32
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Ecnlosures HERE are good, but don't forget to GROUND the case AND insulate it.

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Benjamin
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Posted: 18th Mar 2011 00:47
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If you're serious about doing this the case is pretty much the lowest priority thing you could be doing.



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Dark Java Dude 64
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Posted: 18th Mar 2011 01:01
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Haha i know. I think what ill do is make a simple plexi-glass case when i have the board and everything built, and to make it look cool i might light up the inside with LED's.

Debugging is twice as hard as writing the code in the first place. Therefore, if you write the code as cleverly as possible, you are, by definition, not smart enough to debug it.
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Neuro Fuzzy
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Posted: 18th Mar 2011 09:29
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http://www.ponoko.com/

http://batchpcb.com/index.php/Products

Uhh there was another custom pcb site I saw that was good.

Generally you're best off etching your own PCBs for prototypes, but for a bit larger shipments, you want ta order em. I think some prices I was looking at was $60ish for 4 boards? I don't really remember though...

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The Wilderbeast
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Posted: 18th Mar 2011 23:03
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Your problem is that your PCB is going to end up being extremely complex and, given size constraints, you are going to have to have very fine tracks / pads and probably use a good deal of SMT components - take it from me soldering SMT is not fun.

DIY etching is fine for simpler and larger layouts, but anything more complex than your average circuit and you'll need to have ti done elsewhere.


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Dark Java Dude 64
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Posted: 19th Mar 2011 01:53
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I see. I have heard SMT is no fun, but could be a fun project

Debugging is twice as hard as writing the code in the first place. Therefore, if you write the code as cleverly as possible, you are, by definition, not smart enough to debug it.
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Butter fingers
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Posted: 21st Mar 2011 16:38
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Well if it's a 1 off you could get the case 3D printed for like £300-£500, that'd be a good starter.

One of the companies we work with had their algorithms put on a chip to prevent piracy, and I know that the cost of getting it manufactured (even in china), took a pretty sizable chunk of their 4m investment, so getting your chip made is probably a nono.

i'm interested - you're saying nothing more complex than a NES, but what OS is this thing going to run? Are you basically building a small PC in a box, or are you going for something more elaborate??

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Dark Java Dude 64
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Posted: 21st Mar 2011 23:53
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Ill consider getting it 3d printed, that would allow for translucent plastic, correct?

Yeh, i plan only to make a custom chip if i somehow get a lot of money on this first one, and that's if i put it into production. If and when i need a custom chip for this project, i will use an FPGA, they sound pretty customizable, and relatively affordable, too.

I might give a very basic operating system, somebody on the other thread recommended having an SD card slot as my media interface, and the basic OS would allow you to choose from one of two or more SD card slots... Other things it may do are showing time, having a settable color theme, maybe on an advanced version, there would be ports in the console or controller where a keyboard and mouse would connect,s o you could program the console with the the console, and not on the computer. That would allow for faster emulator-less testing of new games. The last few are things i would put in if i put this console into production... Thanks for your reply

Debugging is twice as hard as writing the code in the first place. Therefore, if you write the code as cleverly as possible, you are, by definition, not smart enough to debug it.
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