Does a Special (Custom) Switch Make Sense for Me?

On paper, it sounds ideal: a custom solution made for your application, ready to plug in and go. But what most people don’t realize is how long that can take, what it costs, and why even simple changes aren’t always so simple. 

Here’s a breakdown of what actually goes into building a special switch, what tends to drive the cost, and how to know if a custom solution makes sense or if a small modification could get the job done faster. 

What’s Involved in Making a Special Switch 

Building a custom switch doesn’t always mean starting from scratch. Sometimes it’s as simple as adding a button, swapping a connector, or adjusting cord length, but other times, it can involve more complex changes. First, the concept gets translated into redline drawings and a BOM (Bill of Materials), which are loaded into the system, and a quote is generated for prototyping and sent to you. Once you have approved the quote and submitted a PO (Purchase Order), the job moves into planning and purchasing. That’s where materials are sourced, timelines are set, and job cards are created. Depending on the complexity, the build then goes to production or into the engineering lab. 

For designs which are simple modifications of an existing product, samples might be ready in a month or two. But add in wireless features or the need for a custom PCBA (Printed Circuit Board Assembly), and that timeline can stretch to three or four months or more. In some cases, spinning a new board, meaning creating and manufacturing a new printed circuit board (PCB) design, adds extra weeks or months to the process but provides necessary functionality which not all manufacturers can deliver. 

For medical applications, timelines are even longer. These builds typically require a full documentation package, including PFMEA (Process Failure Mode and Effects Analysis), control plans, and material compliance forms. Production release in those cases often takes six months or more. 

Even the drafting side can move quickly when all necessary information is complete and accurate. A simple spec can be drafted in a few hours. But once it’s sent to the customer for review, progress slows. Some approvals come back quickly. Others stall for weeks or even over a year. That lag can delay everything. 

The speed of a special switch doesn’t just depend on how fast each team works. It depends on how prepared everyone is from the start. 

What Makes It More Expensive   

Customization adds costs, especially when nothing from previous designs can be reused. If existing parts or testing data cannot be applied, work begins from the ground up, which increases engineering, documentation, and internal setup time. 

Volume plays a big role too. When orders are placed in larger quantities, the upfront development cost can be spread across many units. But for smaller orders, the same cost is distributed among fewer switches, which makes the per unit price higher. 

Even small changes can have ripple effects. Something as simple as a new label or connector may require updated drawings, new approvals, or compliance documentation. That is why, whenever possible, modifying an existing design tends to be the faster and more cost effective option. 

Why Things Get Delayed 

Delays can happen for a variety of reasons, often tied to the flow of information and the coordination required between teams. When specifications, approvals, or label details take extra time to finalize, progress may slow until everything is aligned. 

Internally, priorities can shift as well. Drafting and engineering teams often manage multiple active requests at once. If one project is waiting on clarifications or signoffs, another may move forward in the meantime. 

The best way to keep things moving smoothly is to make sure all key information is gathered early and to maintain clear communication throughout the process. 

Custom vs. Modified: What Actually Makes Sense 

Not every job calls for a full custom switch. If the quantity is low, the budget is tight, or the change is minor, modifying something that already exists often makes more sense. 

Modified switches still address specific needs, but they’re faster to build, easier to approve, and usually cheaper to produce. Custom designs make the most sense when performance requirements are truly unique and require brand alignment.

When you’re deciding between the two, think about the performance, timing, and cost. If a tweak can solve the problem, that’s often the better path. But if your application truly calls for something new, a custom switch might be worth the time. 

Final Takeaway 

Custom switches can be an excellent solution when the need is well defined, and the benefit is worth the time. 

They are not a bad idea, but they are not always the right one for every situation. When project timelines are right, volumes are small, or costs are a concern; a modification can often deliver the same functionality without the added steps. 

If you are unsure which direction makes the most sense, our team can help you evaluate both paths based on your timeline, volume, and application needs. 

Date Uploaded 10/17/25

In collaboration with Dave Drouin (Applications Engineer) & Christian Smutnick (Applications Engineer)