Examples lying around in my house: Bathroom scale: lovely it powers up when you tap it, but eats up 2 button cells a year for a few dozen uses a year Kitchen scales, bit more use, at least once a day but again 2 button cells a year electronic caliper: Same, eats up 1 button cell a year, just sitting in my toolbox Strangely enough none of our kids toys with batteries seem to suffer from this problem How much extra cos…
> ” How much extra cost does a hard on/off switch add to the bill of materials?” BoM cost is not the whole story; a physical switch can greatly complicate an assembly, and may require hand-soldered wires. In addition to those cost-related factors, external switches are usually quite ugly, and getting them right can be very challenging, so it’s much easier to just omit them.
It's no different to any other bad design. It could be better.
All phones and computers can be completely powered down. They're hardly ugly switches.