How Hardware Startups Use Functional Testing to Catch Bad Boards

Episode 55 of Hardware Startups with Fexingo. Lucas and Luna dive into why functional testing — not just flying probe or boundary scan — is the unsung hero of hardware quality. They break down a real case: a medical device startup that shipped 500 units before discovering a firmware-hardware timing bug that only surfaced under load. The fix added a $3,500 functional test fixture that caught the issue in under 30 seconds per board. Lucas explains the difference between structural testing (does the solder joint exist?) and functional testing (does the thing actually do its job?), and why startups often skip the latter until a field failure forces their hand. They discuss test coverage, fixture design, and the hidden cost of returns. If you're building hardware at small scale, this one could save your reputation. #HardwareStartups #FunctionalTesting #DFT #PCBTesting #MedicalDevice #FirmwareBug #TestFixture #QualityControl #HardwareReliability #StartupManufacturing #ElectronicsTesting #BusinessAndTechnology #FexingoBusiness #BusinessPodcast #LucasAndLuna #Engineering #Prototyping #Manufacturing Keep every episode free: buymeacoffee.com/fexingo