MVP is just the beginning – not a time to celebrate
Imagine you just finished a sprint where your team built the first working prototype of a new device – light, flexible, with backlighting and touch. The client is excited. The MVP works. But now comes the real challenge: how do you move from this test version to full production without losing control over quality, costs, or schedule?
This is exactly the question that Polyend, a music gear company from Poland, asked when designing their next-generation controller. Their goal was to make something functional, light, nice-looking, and strong. The MVP came quickly – thanks to printed electronics. But moving to production needed a new approach.
This guide takes you through the most important steps of that process. We’ll show you how to avoid common mistakes, keep control even as scale grows, and learn from each sprint. This is not theory – it’s a real map based on actual projects.
PMs’ fears: “It’s too early to scale”
Many PMs are afraid to scale a project using a new technology – especially when it comes to production. MVP is a safe zone: small volumes, fast decisions, freedom to change. But as production grows, pressure increases – on documentation, parts availability, process repeatability, and cost control. This often leads to decision paralysis.
Common questions at team meetings include: “Isn’t it too soon to scale?”, “Can we be sure it works in bigger volumes?”, “What if changing the ink or film raises our costs?” These are good questions – and instead of ignoring them, they should guide the planning.
Scaling shouldn’t be a big jump into the unknown, but a well-planned process with decisions based on data, tests, and iterations. Key tools: clear checkpoints, flexible project documentation, and a tech partner who can do more than just deliver – they help assess risks and suggest solutions. With structure, most risks can be spotted before they become costly errors.
Most important: don’t leave scaling decisions for “later.” Starting to think about scalability during MVP gives you an advantage. The earlier you plan, the less each next step will cost.
Summary:
- MVP is not just for show – it’s your source of real data and a starting point
- PM doubts are normal – and can be managed through iteration
- Best time to plan for production is not after MVP – but along with MVP
- A good tech partner is not just a supplier – but someone who helps manage risk
Step 1: Collecting MVP Data – What to Know Before You Scale
Before ordering the first production batch, take time to look at your MVP not just as a tech win, but as a learning tool. Now is your best chance to gather data that can prevent expensive mistakes later. MVP is perfect for user testing, environmental trials, and checking technical limits.
It’s important to know which components worked best, whether lighting is even under different conditions, and how conductive layers behave after thousands of bends. This helps you make good scaling decisions, improve design, and understand the limits of your technology.
In Polyend’s case, they tested their prototypes with musicians in real-life conditions. Useful data included wear on the touch layer and light stability after long use. With this data, they could verify materials and get closer to production standards with every version.
Summary:
- MVP gives you valuable data on component behavior
- User tests and cycles reveal problems early
- This data helps shape the next product version
Step 2: Validation and Documentation – Before You Order 1000 Units
Scaling without documentation is like driving without a seatbelt – it might work, but the risk grows with each step. As you move from MVP to early production, you must ensure not just that the product works, but that it works the same every time.
Make sure your team has a full BOM (with versioning), technical drawings with tolerances, and process specs – like drying parameters, temperatures, and test suggestions. This makes production easier and helps plan timelines, budgets, and quality control.
A smart step is to do a pre-series – a small test batch (50–100 units) to check not just the product, but also logistics, packaging, labeling, and EOL testing. Polyend used this phase to compare lighting options and connector types. Their final design choice was based on real data – not guesses.
Summary:
- Before scaling, your documentation must be complete and consistent
- Pre-series help test not just the product but also the process
- Good validation reduces risk of costly mistakes in mass production
Step 3: Change Management – Don’t Get Lost in Iterations
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With printed electronics, changes will happen – and that’s okay. Iteration is part of innovation. But if changes are not tracked or tested, they create chaos. Scaling without change management is a recipe for delays and costs.
Every change – new ink, different substrate, updated process – should have a clear record: cost impact, time impact, quality risk. This helps decide if the change is worth it, and plan validation tests.
You don’t need complex tools. A BOM version log in Excel or Confluence is enough – as long as every update has a date, scope, and owner. Approve each change with a cross-team group: R&D, quality, purchasing. This builds transparency and prevents surprises in production.
Summary:
- Every change brings risk – manage it like a process
- Versioning BOMs and files is key to scalability
- Every tech change needs a test + documentation + approval
Step 4: Communication with the Partner – Not Just a Supplier, but a Collaborator
A printed electronics supplier today is more than just a part maker. In complex projects, their role grows. They’re not just a supplier – they’re part of the project team. The earlier they’re involved, the better they can spot risks, optimize the design, and choose the right materials.
A good practice is to work in sprints – with roadmap reviews, regular checkpoints, and a shared progress dashboard. This helps spot timeline changes, test tech assumptions, and react to problems quickly. Polyend used this model – their supplier didn’t just deliver but also advised, tested materials, and helped improve each prototype.
A good production partner saves time and acts as a safety net when things change. They understand your goals, know tech limits, and suggest options before problems become blockers.
Summary:
- A production partner is part of your development process
- Shared sprints and dashboards keep progress on track
- Good collaboration helps spot and solve problems early
Step 5: Scaling – How to Grow Without Losing Control
Scaling isn’t a jump – it’s a controlled, step-by-step process. The biggest mistake is thinking you can just “copy-paste” the MVP into mass production. In reality, higher volume brings new challenges: logistics, automation, and quality control must evolve.
Start with a ramp-up plan – 100 → 500 → 1000 units. This allows for real testing and process tuning. At each stage, improve small things – packaging, quality control, communication.
Automation matters – not just in machines, but in documentation, EOL testing, and reporting. With this setup, scaling doesn’t stress the team. Plan for logistics, storage, and returns too – it all affects your ability to grow smoothly.
Summary:
- Scaling is not one step – it’s an iterative process
- A ramp-up plan helps manage growth safely
- Automation and logistics are key parts of scaling
Final Summary: Scaling is a Marathon, Not a Sprint
Scaling a printed electronics project isn’t just about volume. It’s a complex process that needs a smart strategy and readiness for iteration. A PM who understands that each stage brings new challenges – materials, logistics, quality – will keep the project on track.
The biggest threat isn’t the technology – it’s lack of change control and poor communication. Scaling is the moment when small MVP mistakes can become big problems. That’s why you need clear checkpoints, versioning, and a well-designed change system.
Printed electronics gives you light, integrated solutions – but only works fully when it’s part of a well-managed process. If you know when to collect data, how to validate changes, and who to work with – you can scale smoothly and with confidence.
Summary:
- Printed electronics is a great opportunity – but needs structure
- Scaling is a marathon – you need checkpoints and version control
- The tech works, but process decides success
What’s next? Let’s talk
We don’t claim to know it all. But we do know how scaling looks from the inside – from production, materials, and testing. If you want to check if your project is ready to move to production, book a technical call with us.
We won’t send you an offer until we’re sure we can really help. In the spirit of the Sandler method: it’s your decision. We just make sure it’s based on facts.