Explanation of Cost Relative to Customization
The Hidden Complexity Behind ‘Simple’ Changes
Ever hear someone say, “It’s just one little change, how expensive can it be?”
We get that a lot. On the surface, modifying a foot switch might seem like a quick fix. Maybe you want a shorter cord, a different connector, or one extra label. But once that request hits engineering, things can get more complicated than they first appear.
If you have ever been caught off guard by a quote that felt higher than expected, this breakdown will help explain why even the smallest changes can set off a chain reaction behind the scenes.
Not All Customization Is Created Equal
Not every request falls into the same bucket. That is where confusion usually starts.
A standard product is something we already build, test, and stock. these move through production quickly because everything has already been designed, validated, and approved. On the medical side, however, none of our foot switches are considered standard. every medical switch is classified as either a special or a custom build.
A modified switch (sometimes called a Product Line Extension) starts with a standard base but includes minor changes like cord length, custom colors, or a specific connector. Even if the outside looks the same, these updates often require new drawings, part numbers, and validation.
A fully custom switch starts from the ground up. It might involve entirely new tooling, changes to housing or treadle shapes, custom PCBs, and additional testing for certifications like IPX8.
What sounds simple, like swapping a connector or adding a toe loop, can sometimes push apart from “modified” to “custom” depending on how it impacts manufacturability, sourcing, or internal layouts.
What Actually Drives the Cost Up
Customization does not just affect materials. It changes the workflow across multiple departments. Some of the biggest cost drivers include:
- Tooling or fixturing to accommodate new housing, cords, or PCBs
- Custom components like connectors or specialty-colored materials
- Spinning a new PCBA, which alone can cost over $1,000
- Small quantity buys that eliminate volume pricing
- Redoing drawings, part numbers, software, or test specs
Even packaging is not immune. A special carton label might require sourcing new base stock, working through multiple vendor proofs, and getting final sign-off. That process alone can add weeks and unexpected cost.
How You Can Help Keep Things Smooth
The earlier we understand what you are trying to accomplish, the better we can guide you toward the most cost-effective solution. Engineering is not just waiting for perfect specs. We often help propose designs based on what you need the switch to do.
Here is how to make your request easier to evaluate:
- Share drawings, photos, or details about the environment
- Explain what problem you are solving, not just the part you want
- Let us know if it needs to match the existing equipment
- Mention timelines, volumes, or certifications early
When we have context, it is easier to recommend smart changes that avoid spinning new boards or tooling.
Final Thoughts: It’s About More Than Just the Part
We are here to make sure the switch you receive works safely and reliably in your environment.
Even small requests can create a domino effect through documentation, materials, engineering, and testing. That is why customization is less like flipping a switch and more like opening a new project. There are layers to consider. Each one adds complexity.
Date Uploaded 10/01/25
In collaboration with Dave Drouin (Applications Engineer)
Custom Footswitches
Linemaster’s custom footswitches are designed to meet specific user requirements, offering a range of features such as various pedal configurations, wired and wireless options, and customizable LED indicators. These footswitches provide reliable, durable solutions tailored to enhance functionality in diverse applications.
