There’s nothing worse than investing your team’s time and company’s money designing, sourcing, and producing a new product, only to find out after everything’s done, everything’s tested, everything’s good to go that a critical part of your device is going away and you have no direct replacement capable of providing the same form, fit, and function.

It can suck the life out of you and take away all your enthusiasm for the new product because now you have to go back to square one and start over again

My team and I have been there ourselves and worked with many other OEMs who have experienced the complete heartbreak of end-of-life / end-of-sale / end-of-everything when designing and producing a device

In fact, most teams think about end-of-life only when a part is going away. The best time to think about product lifecycles, however, is the day you specify the part.

Here’s why it’s critical to work with a partner that stays on top of component lifecycles, plus what’s coming for 1D scan engines that makes this more urgent right now

Understanding Product Lifecycles

To avoid challenges revising or redesigning your product, you need to understand where the key devices and components you rely on exist in their individual product lifecycles. This is especially important before you select any component that will become integral to a new product that you expect to be in production for the next 3 to 10 years.

When I hear about devices or components going end of life, my heart starts to race a little bit, because I was a product manager, and I know how many customers, end users, and their end customers could be instantly affected because a certain item is no longer available.

It’s the old saying, “If I only knew then what I know now.”

That’s why I really enjoy it when we’re invited in very early as a customer embarks on a new project. That way we have an opportunity to sit with them and discuss all the device and component requirements.

When we see something, like an older model scan engine being specced that we know will go end-of-life within a short window, we have an opportunity to point that out and direct the customer to a better solution. It’s always best when we can start off on a fresh slate with a long runway, rather than dealing with a shorter product lifecycle deadline.

A “Live” Example of End-of-Life

Let’s take this out of the abstract for a moment and discuss something that is impacting many OEMs. Zebra is sunsetting its 1D scan engines at the end of this year. That means if you’re building or operating equipment that depends on a 1D scan engine, and you haven’t made plans, you are going to experience some heartache very soon. You will likely find that the replacement 2D scanning engine has different mounting, power, and electro-optical requirements that can dramatically change the size and weight of your device.

An End-of-Lifecycle Glossary

Let’s take a short sidestep to discuss the many ways that “end-of-life” may show up in commercial specs and product notes. We often see the following terms, and they’re not all interchangeable..

End-of-sale (EOS).

The day a manufacturer stops selling a part. You can still get support, and sometimes still get spares, but new orders for stock stop here.

End-of-life (EOL).

This is the full retirement of a part (unfortunately, it’s often a critical part of your build). There will be no new units, and eventually, no new support either. This is often paired with a formal announcement and timeline.

Last-time buy (LTB).

A short window of time which usually opens with the EOL announcement. This is when you can place a final order for as many components as you need to bridge to your replacement part.

Direct replacement.

A new part the manufacturer (or a partner) offers as a one-for-one substitute for the part being retired. This is usually the cleanest path forward that has the same form, fit, and function as the current component in use today.

Form, fit, and function.

The three-part test for whether a replacement actually drops in: same physical form (size, mounting), same fit (mechanical, electrical interfaces), same function (what it does and how it behaves). If your new component misses any of the three, you’re not replacing, you’re redesigning.

Why EOL May Not Be Caused By What You Expect

An EOL event isn’t always based on a conscious manufacturer choice, and the announced date isn’t always the date you get.

Manufacturers can get caught in a situation where their factory or supply chain is damaged, and they can no longer produce the device or component they were manufacturing. This could be due to a flood, a fire, a supply chain disruption, or even a war. These situations are primary reasons why you may want to source a secondary supplier as a backup for critical components in your device.

For example, during COVID, the Panama Canal drought restrictions, the tariff wars, and now the Strait of Hormuz disruptions, a component might be manufactured but unable to reach the supply chain.

We have also seen cases where a component has a declared EOL for the end of the year, but supply runs out faster than expected, bringing it to EOL in August instead. If you were waiting until the last minute to make a purchase, you may be out of luck as supplies dwindle.

Unfortunately, we have seen the case where an OEM is sitting with 90 percent of their product built, and now they can’t complete it because they’re missing one or two components. And now you have a production line that’s been brought to a standstill. It can be extremely devastating.

Back to the Future with 2D Scanning

Let’s get back to that 1D scan engine sunset, and why “just swap in a 2D scan engine” isn’t as easy as it sounds. As I mentioned earlier, Zebra has announced it will end-of-life 1D scan engines at the end of the year.

Now many customers are facing a decision.

They respect Zebra’s quality, durability, advanced performance, programming, and manageability, so they want to continue using Zebra scan engines. However, it may result in a total redesign of their product, because 2D engines are generally larger, can draw more power, and may have different interfaces. They can also be more expensive, requiring the OEM to charge more to their customers.

A change from one component, such as one scan engine to another, often carries many implications, including device design, mechanical integration, electro-optical considerations, and often the biggest concern of all — regulatory implications.

Often, if you introduce a completely new module into a device that’s already been certified — regulatory, UL, FCC, FDA, laser safety — you will need to have the new and improved device recertified as well.

All of this has led some OEMs to seek alternatives.

“What’s the Right Choice for My EOL Component?”

When customers ask this question, I try not to give the dreaded response, but it’s true, “There’s no right answer, so it depends.”

For example, we designed a drop-in replacement when Zebra end-of-lifed its SE3307 scan engine. We brought 20,000 units of the original into inventory to provide a bridge for customers, and then manufactured the DSM-710 replacement to match the form, fit, and function of the SE3307. Plus we created modular housing, so the next EOL won’t trigger another redesign.

The reality is there are five different paths to choose from. It’s my job (and my colleagues’) to guide you down the right path. Here are the most common:

• Last-time buy. This is the choice when you need a little more time. You lock in inventory and buy yourself some runway.
• Direct replacement. This is the best choice when a newer component with the same form, fit, and function is available from your current manufacturer.
• Migrate to a Zebra 2D engine and redesign. This is the choice made by customers that are committed to the Zebra ecosystem, and can absorb the changes, costs, and recertifications required for their device.
• Switch manufacturers (Honeywell, Newland, others). When Zebra isn’t the right fit for the application or the price point, there may be another option available.
• A custom-engineered replacement — when volume justifies it and none of the above is clean. This is where the DSM-710 came from.

What Makes Dolphin Your Partner of Choice

We look at all the available options you’re facing and work toward the best fit for your project. We don’t want you using a component with a short runway and we also don’t want you paying extra for unused features. We try to map out the best solution for your specific needs. In any case, we prepare you for what’s coming in the lifecycles of your component parts. We want you to look at us as your AIDC partner of choice.

Recently, a customer told our team , “Most manufacturers don’t give me this kind of heads-up, so I really appreciate it. It’s awful that the part is going away, but knowing this gives us a chance to react.”

Here is what we provide around lifecycle management:

• We track the lifecycle for every component our customers depend on, not just the ones currently shipping.
• We don’t allow surprise situations to occur.
• We stay close to Zebra engineering and product management. We’re located a few miles from their Long Island headquarters, and that proximity is a working relationship, not a marketing line.
• We hold US-based inventory ahead of EOL events, not in reaction to them.
• Our engineers can design custom solutions when no off-the-shelf options fit.
• We’re honest when the right answer isn’t a Zebra part.

That’s why it’s even more critical to have a real good direct relationship with a partner like us. We’re able to understand what you need to accomplish, down to the smallest details necessary. We help to ensure that if there are any bumps in the road, we can at least tell you about them beforehand and engineer a way around them.

If you’re building or operating equipment that depends on a 1D scan engine, the December 2026 deadline is real and the time to plan is now. And if you don’t know where your other critical components sit in their lifecycles, that’s the first conversation to have with us.

Working with Dolphin Data Capture.

We are recognized as one of the largest OEM barcode scan engine suppliers in the world for clients ranging from Fortune 500 enterprises and top-tier medical device OEMs to agile small and mid-sized businesses.

We integrate the world’s leading barcode technology into medical devices for the top 10 OEM medical companies – where accuracy isn’t optional and people’s health depends on it.

If we can solve problems for them, we know we can solve problems for you.

Contact the Dolphin team at 516-405-3990 or info@dolphindc.com and have your questions ready!