Electronic and mechanical design are fundamental aspects of developing modern electronic devices – including those that incorporate display modules. Screens have become essential components across a wide range of industries, including sectors with particularly high requirements such as industrial automation, healthcare, aerospace, automotive, and defense. Their proper integration with electronics and mechanics is crucial for the correct functioning of the entire system. Moreover, in many devices, the screen is often the first element to signal a malfunction – even if the issue doesn’t directly concern the display – which is why the design process must be especially precise and well thought out.
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The design process – both mechanical and electronic – requires close collaboration between engineering teams and careful consideration of numerous factors, such as the device’s purpose, environmental conditions, component characteristics, durability, performance, and electromagnetic compatibility (EMC). In this article, we outline the process step by step.
Electronic Design
Electronic design begins with defining technical requirements, such as selecting the main processor, specifying the necessary interfaces and connectors, and determining the PCB dimensions. These requirements are obtained through detailed consultations with the client to understand their needs fully. Only that way can a solution be fitted to the final device.
Based on the agreed-upon technical requirements, the design work commences, encompassing the development of circuit schematics, the selection of suitable components, and the creation of the PCB layout. Each of these stages is described below:
- Schematic Design – Schematics illustrate how components such as integrated circuits, resistors, capacitors, diodes, and transistors are connected. Each component has a dedicated symbol, and lines represent the electrical connections between them. Schematics are the foundation for PCB layout design and are essential for later validation, analysis, and diagnostics.
- Component Selection – This stage directly affects the reliability, efficiency, and cost of the project. Factors to consider include technical parameters (voltage, current, frequency, tolerances), market availability, physical size, and compatibility with other system elements.
- PCB Layout Design – Placing components on the printed circuit board requires particular care. A poorly designed layout can lead to electromagnetic interference, cooling issues, or energy inefficiencies. The layout should be optimized to ensure proper signal flow and effective heat dissipation.
Electronic design also involves developing firmware and drivers that control the device. This may involve programming microcontrollers or configuring operating systems that manage the entire system’s functionality.
Mechanical Design
In this phase, mechanical engineers conduct detailed analyses of the enclosure’s functionality, shape, and dimensions, as well as explore possibilities for mounting and integrating other components. Material selection plays a crucial role – materials must provide adequate resistance to environmental factors such as dust, moisture, extreme temperatures, or mechanical damage, depending on the specific operating environment.
Special attention is given to 3D modeling. This technology enables engineers to precisely replicate all details and identify potential issues early on, such as mismatched parts. These 3D models also form the basis for 2D technical documentation used in the manufacturing process.
Increasingly, 3D printing is used in mechanical design to speed up the creation and modification of physical models. It enables the rapid production of prototypes such as brackets, mounting elements, or entire housings, allowing engineers to verify fit, functionality, and ergonomics before mass production. 3D printing also allows engineers to test different structural variants without the need for costly molds or specialized tools, increasing flexibility, shortening revision cycles, and reducing product development costs.
Integration of Mechanics and Electronics
Successful integration of electronics with mechanics is vital to the overall success of a project. It requires close collaboration between engineers from both disciplines. For components requiring precise mounting, such as display modules, the enclosure must be designed to ensure the proper positioning and stability of all parts. Mounting holes, connectors, and protective features such as gaskets that prevent the ingress of dust and moisture must also be carefully planned.
Integration also includes thoughtful cable management. Wires and connectors must be arranged to ensure safety, functionality, and ease of maintenance.
Thermal management is another critical consideration, especially for power-hungry devices. Excessive heat can reduce performance, shorten component lifespan, or even lead to failure. Depending on the system’s needs, designers use heat sinks, fans, thermal pastes and pads, as well as active or passive cooling systems.
Prototyping, Testing, and Validation
Prototyping
Prototyping is a crucial phase that connects electronic and mechanical design. It enables physical verification of design assumptions made in earlier stages. Prototypes allow engineers to assess how the electronic components fit within the enclosure, verify connections, evaluate user ergonomics, and test the entire system in practice. At this stage, design flaws or functional issues can be quickly identified and corrected before mass production.
Testing and Validation
The prototype undergoes rigorous testing and validation to assess the reliability and performance of the designed device.
Technical testing involves verifying the functionality of electronic circuits, ensuring communication stability between components, assessing cooling system performance, and evaluating resistance to overheating. Mechanical aspects are also examined – including the durability of the construction, assembly precision, and ease of use. A crucial part of the process is electromagnetic compatibility (EMC) testing, which ensures that the device is resistant to external interference and does not negatively affect other systems operating nearby.
The process concludes with validation – a formal confirmation that the solution meets all specified technical, functional, and environmental requirements. This includes functional tests, endurance testing, and verification of compliance with relevant industry standards and norms. As a result, the client receives a thoroughly tested and fully operational product, ready for deployment – even in the most demanding environments.
Design Your Device with Unisystem’s Solution Team
Electronic and mechanical design are crucial for the success of any modern electronic device. At Unisystem, since 2010, we’ve been conducting research and development in information visualization technologies. Today, these efforts are carried out by our Solution team, which effectively tackles even the most complex challenges related to integrating display modules into final products.
Our strength is in the close collaboration between electronic and mechanical engineers, as well as the use of state-of-the-art technologies throughout the design process. We deliver durable, reliable, and highly customized solutions tailored to each client’s specific requirements. Our flexible approach and years of experience allow us to execute even the most sophisticated projects with confidence.
In modern devices, the display is more than just a user interface – it is often a critical part of the entire system. When something is wrong, the first signs are usually visible on the screen. That’s why the proper integration of both electronics and mechanics is essential for overall system performance. If you’re looking for a proven and reliable solution – entrust this task to specialists who have spent years building expertise in display integration and information visualization technologies.
Contact us — together we’ll create a solution tailored to your needs.
