This seems to apply across the entire Small Plastic-covered Electronics sector. I worked for an instrumentation/sporting goods manufacturer among others and this reads like I wrote it myself. The CEO, even of a small operation, likely has no idea what the performance characteristics of their devices are. They exist to raise capital and deal with paperwork. We operated at about a 25% bom cost which was muuuuch higher…
> random FCC compliance stuff Nothing better than designing a product and actually producing a batch of it... and then finding out you have some EMI problem requiring a redesign. If you're lucky, you can remedy it by manually adding some shielding tape, if not... you might as well file for bankruptcy in the worst case.
We had a few cases like this that one of the engineers was especially good at solving.
In one, we had a cheaper network switch that was failing one of the limits. One of our engineers walked in with a can of metalized spray paint, applied a single squirt to the inside of the plastic case, and fixed the issue. If you bought one and opened it, you would see a single squirt of silver looking paint on the inside, right where he put his. I've seen a few of these squirts in the devices I've taken apart, so I guess it's not a secret.