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

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Greg

I help companies turn their technical ideas into reality. CEO @Sourcetoad and @OnDeck. Author of Herding Cats and Coders. Fan of squash, whiskey, aggressive inline, and temperamental British sports cars.

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Don’t Fall Into the Trap: Why Startup Software Development Isn’t Like Corporate Development

1 day agoNovember 14, 2024In Startups, Technology

So, you’ve left the corporate world, and now it’s time to build your own startup. You’ve probably managed dev teams before, overseen product launches, maybe even helmed some fancy project management tools that made everything run like a well-oiled machine. You’ve done this before, right? Not exactly. When it’s your startup, everything changes—and, as I’ll explain, if you assume it’ll work the same way, you’re heading for a few surprises.

Startup founders often fall into a dangerous trap when starting a software project from scratch: thinking it’ll be just like building software inside an established company. Here’s why it’s not—and some advice on how to navigate the differences.

1. Switching from Product Manager to Teacher

In an established company, a software team already has two things that give them a serious edge: an existing market and a deep understanding of the business. They’re working within a proven model. Developers in that environment know what questions to ask, can fill in gaps intuitively, and likely understand why they’re building what they’re building.

At a startup, however, your devs are going to need a whole lot more context. They’re not working with familiar requirements—they’re working with your vision, which may be abstract at this stage. If your development team doesn’t understand why something matters, it’s a recipe for ambiguity and frustration on both sides.

Advice: Think of yourself less as a product manager and more as a teacher. Your job is to make sure they understand the core problems, not just the features. Teach them why each requirement matters, help them visualize the end-user, and create that shared language for decision-making. It might feel tedious, but it’s essential to avoid future misalignment and expensive rewrites.

2. Beware of Perfectionism — It’s the Budget Killer

In a large company, products with an existing user base often have to be polished. Features need to be rock-solid, invoices have to be perfect, and everything needs an audit trail. Startups, however, have a different goal: get an MVP in the hands of users fast. It’s a classic trap for first-time founders—focusing on “perfection” and “polish” before knowing if the business model even works.

Startup perfectionism is budget poison. It’s shocking how quickly adding “nice-to-have” features can chew through funding, especially if you’re paying a dev team to build things like automated invoicing or churn management before you’ve even proven people want what you’re selling.

Advice: Ruthlessly strip down your MVP. If a feature doesn’t help you validate your market, it goes on the “later” list. Keep the scope laser-focused on what helps you test your business assumptions. Let the non-essential features wait until you know you have customers who’ll use them.

3. Zen and the Art of the Startup Pivot

Building software for a startup means embracing one cold, hard truth: the business model will change. According to research, 93% of successful startups pivot at least once (and often more). Imagine being asked to go out and passionately sell something that you know might not look the same next year—or next month. It takes a level of zen acceptance that your original idea will likely morph, but that’s what keeps you flexible and ready to capture new opportunities.

For founders, that requires a mindset shift. You have to believe in your product, while also knowing you might be building the “wrong thing” in some way. The focus should be on preserving capital and brainpower for what’s next. The game is less about proving you’re right and more about staying adaptable.

Advice: Budget with pivots in mind. Set your burn rate assuming you’ll need to make big changes. Don’t let ego get in the way of listening to the market, and keep enough gas in the tank for at least one big strategic turn.

4. The Hard Work of Being Your Own “Internal Customer”

Here’s another big one. In a corporate environment, you have internal customers—departments or stakeholders with specific goals that align with the overall company mission. For a startup, the only customer you have is you. You don’t have a preexisting feedback loop from various departments, and you don’t have established success metrics. You have to create that from scratch.

Advice: Start by building an internal customer profile based on your target market, then use that to set clear goals and success criteria for your dev team. If you’re focused on, say, usability for early adopters, set KPIs around usability testing and build from there. By acting as your own “internal customer,” you’re setting a clear direction and saving your team from working in a vacuum.

5. Get Ready to Build AND Sell

Corporate software development often has the luxury of a separate, dedicated sales team to deliver the product to the right audience. As a startup founder, you’re both the builder and the seller. That means you’re not just iterating on software—you’re iterating on messaging, product-market fit, pricing, and maybe even distribution models.

Advice: Factor in time for sales-ready iteration in your dev cycle. As you build, keep track of how each release or update affects the user experience. Ask yourself if the changes make your pitch clearer or simpler and how they align with the current market’s needs. Ultimately, this approach will help you bridge the gap between building the product and ensuring it’s market-ready.

Conclusion

Building software as a startup founder requires a whole different toolkit than you may be used to. You’re part-teacher, part-salesperson, part-zen master, and always the chief budget officer. By recognizing the unique mindset shifts and traps of startup software development, you’re positioning yourself—and your team—for the best chance of success. Focus on creating clarity for your team, set ruthless priorities, embrace change, and never lose sight of the fact that the first version is just the beginning. In the startup world, adaptability isn’t just a skill—it’s the entire game.

Greg Ross-Munro