Remote Controls: From Napkin to Production

Solving problems is what my company does for a living. 95% of the time we solve problems by building software. Over the last few years, hardware solutions have entered our solutions tool box more and more. This is largely due to the fact that you can now hook a bluetooth module to some larger device like a printer. You then handle the data processing on some mobile device. Or, we are write software to live on some small-board machine like a Raspberry PI that monitors water temperature or something. These hardware solutions are however, largely integrations, and not actual hardware development.

So when a client asked us to build them a remote control for their interactive TV system, I thought: how hard can it be? This post tries to lay out some of the lessons I have learned while designing, programming, manufacturing, and shipping a custom-built hardware project from soup to nuts.

Like with any new venture, I didn’t know where to start. I know what a remote control is (I use one every day to watch Youtube videos about bad movies) but I’d never really thought about them. Iterative design works in software… so I figured it wouldn’t hurt to just start with something very simple.

Lesson: Just start with something. Anything. Inertia is the enemy.

Humble Beginnings

I sketched the thing out on a piece of scrap paper. In my infinite creativity I took a generation one Apple TV remote control (which at the time I thought was very cool) and traced it on some scrap piece of paper. As Picasso said, good artists borrow, great artists steal. I then used dime to trace the d-pad, and a pen lid to outline the function buttons. You never think about regrets when you start something, but documenting your first steps will make you more mindful of the process. I wish I still had that napkin, or receipt, or whatever I first drew it on.

Lesson: Keep baby photos and napkin sketches. Looking back gives your perspective.

Fortunately, I did keep the first digital rendering that I translated into Balsamiq (totally the wrong tool for the job.)

Surprisingly, this very basic initial start was good enough to get some general client feedback and approvals. Now the real work began. We had to actually build a remote control. We had a few connections in the set-top-box manufacturing world and knew engineers and account managers at two of the big TV brands. So we reached out and asked for some recommendations.

Contract Manufacturers

We evaluated a few manufactures in Texas, China, and Taiwan. Most of them were up for the task, but none clicked for us. We were looking for a partner who talked to us about the future, about innovation, and brought their own ideas to the table. We didn’t really know what we were doing, but we knew that we would want to push the limits eventually, and having a manufacturing team who got excited about remote control technology was a must.

Lesson: Find partners who share your values.

The process was slow. This was not our wheelhouse, but it was a fun, tangible project, with a single, definite measure of success – something that is often elusive in software development. So we pushed on. In the end, one of our DRM encoding partners introduced us to a manufacture in Hong Kong. They were responsive, helpful, and had US-based project managers.

Lesson: Ask EVERYONE for help. The more people you speak to the more likely you are to get valuable signal from the noise.

Learn About Everything

Our new vendor gave us a ton of options. Did we know that there are a huge number of molds already out there? Ones that look almost identical to our sketches? And that we could easily customize them? No, no we didn’t. So they went to work sourcing three or four demo units from other manufacturing firms they were familiar with. This way we could send our client actual samples to touch and feel without spending tens of thousands of dollars in manufacturing prototypes.

They also began educating us on IR codes, button mapping, and materials design. While the learning curve was steep, it was rewarding and edifying experience. It is so satisfying to be able to design software systems in concert with hardware. When your code jumps into the tactile world it is just so cool. Working hand-in-hand with the manufacturers, we threw ourselves into their processes, language, legal ramifications, and communication patterns.

Lesson: Learn how to communicate with your partners from their perspective. Even if you are a client, you will benefit from speaking their language.

Test, Test, and Test Again

We tested a bunch of the molds, shipping them around the world for client feedback. We also spent a lot of time hallway testing (asking random people walking by to give us feedback). We gave them to our parents and grandparents, friends and children, and basically anyone who would listen. I actually met one of our client’s customers in an airport (identified by a sticker on her luggage) and dragged the poor woman into user test. I had one of the test remotes in my pocket, and the prototype TV system on my laptop’s local server. We didn’t give her any instructions. She absolutely loved it. The customer felt special getting to play with something before the public do. I learnt more in those 15 minutes with her than anything I had read online about remote design and TV interactions.

Lesson: If you are not showing your product to clients along the line, you are not doing your job well.

We evaluated everything: feel, weight, button squishiness, response time, everything. This was a little easier now that we had a few comparison prototypes, but our clients were very particular group of people. The company’s owner was to give final approval; he oversees much of final the public-facing products. We sent two finalists to him, that we could barely tell the difference between. After he made his selection, I asked for his team to ask him the following day if he could tell the difference, and he made the same choice. They were extremely pleased with the design and functionality – the owner said:

This is so good it makes everything else look embarrassing
Our Client

Which might be the highest compliment anyone has ever paid me.

Lesson: If you want to do something well, take every part of it seriously.

The Trouble Begins

Once we had approved from the client, we gave the go-ahead for manufacturing. Then the Hong Kong problems started. The protests throughout the metro area brought manufacturing to a temporary halt. Workers could not even get to work. Suppliers couldn’t access roads. The whole city came to a halt.

Then the mold vendor disappeared. Our manufacturer had sourced a ready-made mold from another company. One day, our project manager called us in tears because the owner of the vendor’s company had not shown up to work. No one knew where he was. The political situation had made is so that asking questions was not encouraged. Say what you want about the American political system; you don’t have to worry about your business partners not showing up after a rally.

So the search began for a new mold manufacturer. Unfortunately this meant once again going through the approval process with our client. This time it was a little easier because we had learned so much from the first round. After a ton of time and a huge DHL bill, we finally had a new mold, and client approval. Eventually the factories started opening up again, and we were ready to go!

COVID-19

Then the factories shut down. COVID-19 hit China hard, and Hong Kong with it. Almost as soon as we had started printing boards, everything went into quarantine. At the beginning there was some pushback from suppliers, clients, contractors, and even our project managers. But as the scope of the pandemic become obvious, everyone became more tolerant and understanding. It still added almost three months of delays to the project. All while my developers got to move to the comfort of their homes and continue working. More perspective.

Lesson: Like everything in life, it came down to lots of failure followed by perseverance. Feeling frustrated every morning and swearing a lot are the steps in between. With enough failure, swearing, and pig-headedness, stuff works out somehow.

The two final versions — Down to two finalists

The Final Stretch

The day those first four remote controls arrived in our office felt like we had landed on the moon. We wiped them down with disinfectant wipes and went to work (no one really knew anything about COVID back then!) We did find a small manufacturing defect with the battery connection in two of the remotes, but it was easily remedied.

Then programming began. This went a little smoother due to the fact that my team had done this type of work many times before. We already had IR code programming tables, IoT systems for managing multiple receivers in close proximity and tools too complicated for me to understand that can change the TVs’ or set-top-boxes’ input expectations. It felt… easy, but in reality we had been working on those particular problems for over six years, so the perspective of a thousand small failures didn’t feel anywhere as monumental as the hardware production.

Lesson: Trying new things puts things you already know into perspective.

Where We Are Today

Today, there are tens of thousands of these remote controls out in the wild. People write reviews about them online, and my client mentions them in interviews with international news publications. As a software guy, it continues to be one of those things I’m proud of, and still shocked by the success we achieved from such humble beginnings.

Lessons

Just start with something. Anything. Inertia is the enemy
If you are not showing your product to clients along the line, you are not doing your job well
Keep baby photos and napkin sketches. Looking back gives your perspective
Learn how to communicate with your partners from their perspective. Even if you are a client, you will benefit from speaking their language
If you want to do something well, take every part of it seriously
Like everything in life, it comes down to lots of failure followed by perseverance. Feeling frustrated every morning and swearing a lot are the steps in between. With enough failure, swearing, and pig-headedness, stuff works out somehow. Why do I have to keep relearning this?
Trying new things puts things you already know into perspective

I’ll probably regret writing this. At the very least, I’ll cringe reading it in a few months. But here we are.

Lately, we’ve been getting a wave of client requests asking us to evaluate software they built using AI tools. These aren’t engineers. These are business folks using increasingly powerful AI products to try and build functioning systems. And to be completely honest, the results are both impressive and a bit alarming.

People are building whole applications on their own. Backends, frontends, user interfaces, even some database logic. Sometimes they even look good. These are smart people who don’t know how to code but have managed to produce working systems.

The problems show up immediately when we start reviewing the internals. The code is usually a mess. In many cases, it would be extremely difficult to maintain or extend. And if you need to move that code from the platform it was created in to a cloud provider like AWS, you’re going to hit a wall. These platforms wrap everything in layers of scaffolding that make portability a nightmare.

Security is worse. We’ve found plaintext credentials scattered across files. We’ve seen SQL injection vulnerabilities that shouldn’t even be possible in modern frameworks. We’ve seen structural issues that would get flagged in a freshman CS class.

Despite all that, what people are creating are legitimate prototypes. They’re functional. They run. But when you’ve put a few weeks into building something, and you show it to a software engineer, it’s hard to hear that your shiny new thing needs to be rebuilt from scratch.

I want to be clear. I am not anti-AI. Almost everyone at my company uses AI tools every day. We use Copilot, Cursor, ChatGPT, Claude, and more. We build out frontends with tools like v0 and Lovable. These tools have changed how we work.

Some of our engineers report productivity improvements of 30 to 40 percent. That’s not a rounding error. That is a major shift. But they are still writing the code. They are reviewing it. They are checking for performance, clarity, security, and maintainability. They are not letting the tools decide architecture. They are using AI like they use autocomplete or linters, but with more power behind it.

This is also where expectations need to be adjusted. These systems will not save you 90 percent on development. They will not let you skip engineering altogether. But if they save you 30 percent, that’s a real gain. Imagine you’re building a house. The general contractor says it’s going to be $500,000. You tell them you already did the blueprints, filled out all the permits, and figured out the site plan using some AI tools. If they came back and said, “Alright, I’ll knock 30 percent off,” that would be the best deal of your life. That’s where we are today with AI-generated software. A solid start. A real value. Not a replacement.

For me personally, AI has made it fun to write code again. I haven’t been a working programmer in over a decade, and most modern toolchains are enough to scare me off. Now, with the right assistance, I can build something without getting stuck on Docker configs and dependency mismatches. That’s a big deal.

In the startup world, AI-first development is everywhere. Most of the current Y Combinator batch is using AI tools to write the bulk of their code. But those teams are highly technical. These are engineers using better tools, not tools replacing engineers.

So for non-developers using AI to build products, here are three things you should keep in mind:

These tools are great for building prototypes. If you build something yourself, you will understand it better and will be a better partner to your engineering team. That matters.
These tools can help you build usable frontend components. You probably won’t want to go live with them, but they can get you close enough to work with a real development team.
If your app is small, non-critical, doesn’t store sensitive data, and lives entirely in its native platform, you can probably keep it running. That’s fine for internal use or personal projects.

One day, you’ll be able to speak an app into existence and deploy it with a voice command. It will be fast, secure, and beautiful. But today, you still need an experienced software engineer to check your work before you send real data through it. That’s just where we are right now.

The upside is huge. We can now get experts from other domains to build working prototypes and test ideas without needing an engineering team on day one. That’s powerful. But if your product is going to handle sensitive data or support real users, bring in someone who knows what they’re doing. Not because the AI is bad. Because the stakes are high.

Greg Ross-Munro