The Art of the Teardown: Learning by Taking Things Apart
I have a confession: I can't resist taking things apart.
Broken coffee maker? Teardown.
Old laptop? Teardown.
Thrift store gadget? Teardown.
Competitor's product? Definitely teardown.
This isn't destructive curiosity—it's systematic learning. And it's one of the most valuable skills I've developed as a hardware engineer.
Why Teardowns Matter
You can learn a lot from datasheets, CAD tutorials, and YouTube videos. But nothing compares to holding the actual hardware and seeing how someone else solved the same problems you're facing.
What You Learn
1. Manufacturing Decisions
- Why they used screws vs. clips
- How they routed cables
- Where they saved costs
- What they over-engineered
2. Design Tradeoffs
- Thermal management strategies
- Structural reinforcement choices
- Component placement logic
- Assembly sequence constraints
3. Failure Modes
- Where stress concentrates
- What wears out first
- How water intrusion happens
- Why things break
4. Cost Engineering
- Cheap vs. expensive components
- Where corners were cut
- What's surprisingly robust
- Hidden quality indicators
5. Clever Solutions
- Elegant mechanical tricks
- Unexpected material choices
- Smart assembly techniques
- Reusable design patterns
My Teardown Process
I've developed a systematic approach over the years:
Phase 1: Documentation (Before Touching Anything)
- Photograph - Every angle, every label, every detail
- Weigh - Total weight, then component weights
- Measure - External dimensions, tolerances
- Research - Find patents, manuals, reviews
- Hypothesize - Guess how it works before opening
Phase 2: Non-Destructive Disassembly
- Remove fasteners - Keep them organized by location
- Separate components - Gently, preserving connections
- Document connections - Photos of every cable/connector
- Label everything - Masking tape and markers
- Note assembly order - How it goes back together
Phase 3: Analysis
- Identify components - Part numbers, manufacturers
- Trace circuits - Follow power, signals, ground
- Measure - Voltages, resistances, dimensions
- Test - What still works? What's broken?
- Compare - How does this differ from alternatives?
Phase 4: Synthesis
- Sketch - Recreate the design in CAD or diagrams
- BOM - Build a bill of materials with costs
- Write - Document findings, insights, questions
- Share - Blog post, video, or internal report
- Apply - Use learnings in my own designs
Memorable Teardowns
Let me share a few that taught me the most:
1. Nest Thermostat (3rd Gen)
What I learned:
- The display is the PCB (genius cost reduction)
- Thermal mass matters for accurate sensing
- User experience drives mechanical design
- Premium feel comes from weight and materials
Applied to Thios:
- Integrated displays in Thiosphere™ sensors
- Careful sensor placement for accuracy
- Weighted bases for stability
- Anodized aluminum for premium feel
2. Dyson Vacuum (DC25)
What I learned:
- Transparent housings build trust
- Cyclonic separation is elegant engineering
- Ball joint mobility is underrated
- Serviceability can be a feature
Applied to Thios:
- Transparent enclosures for Saunosphere™
- Airflow optimization in Agrosphere™
- Modular, tool-free assembly
- User-replaceable components
3. iPhone 12 Pro
What I learned:
- Integration density is insane
- Adhesive is structural
- Repairability is a choice
- Precision costs money
Applied to Thios:
- Compact sensor modules
- Strategic use of adhesives
- Designed for repair (opposite of Apple)
- Cost-conscious precision
4. Cheap Amazon Humidifier
What I learned:
- Where cost-cutting breaks things
- Why some products fail fast
- The value of quality components
- How not to design for longevity
Applied to Thios:
- Avoid cheap ultrasonic transducers
- Invest in good seals and gaskets
- Use proper wire gauges
- Design for 10+ year lifespan
Tools of the Trade
You don't need much to start:
Essential Tools
- Screwdriver set - iFixit kit is worth it
- Spudgers - Plastic pry tools
- Tweezers - Precision and reverse-action
- Multimeter - For electrical analysis
- Calipers - Digital, 0.01mm resolution
- Camera - Phone is fine, DSLR is better
- Notebook - Physical or digital
Nice to Have
- Microscope - USB microscope for PCB inspection
- Heat gun - For adhesive removal
- Soldering iron - For desoldering components
- X-ray - If you have access (I don't)
- CT scanner - For non-destructive internal views
Software
- CAD - Fusion 360, FreeCAD, OnShape
- Diagramming - Draw.io, Lucidchart
- Note-taking - Obsidian, Notion, Markdown
- Photo management - Lightroom, Google Photos
Legal and Ethical Considerations
Teardowns exist in a gray area. Here's my framework:
Legal
- Bought it? You can tear it down for personal learning
- Borrowed it? Get permission first
- Competitor's? Buy it legitimately, don't steal
- Patented? Teardown is fine, copying isn't
- Trade secrets? Reverse engineering is legal (in US)
Ethical
- Don't copy - Learn principles, don't clone
- Respect IP - Patents exist for a reason
- Credit sources - If you publish, acknowledge the original
- Consider impact - Will this harm the original maker?
- Add value - Don't just tear down, teach or improve
Teardown as Content
Some of my favorite creators do teardowns:
- iFixit - Repairability scores and guides
- EEVblog - Electronics teardowns and analysis
- Lumafield - CT scan teardowns (incredible)
- Technology Connections - Deep dives on appliances
- This Old Tony - Machining and mechanical teardowns
I'm planning to add teardowns to this blog. Format TBD, but expect:
- Detailed photo galleries
- Component identification
- Cost analysis
- Design critique
- Lessons learned
What I'm Tearing Down Next
Current queue:
- Inkbird ITC-308 - Temperature controller (competitor to Thiosphere™)
- Anova Precision Cooker - Sous vide (thermal control insights)
- Xiaomi Air Purifier - HEPA filtration (relevant to Agrosphere™)
- Oura Ring Gen 3 - Wearable sensors (miniaturization lessons)
- Prusa i3 MK3S - 3D printer (manufacturing tool study)
Vote in the comments: Which should I do first?
Teardown Challenges
It's not all fun. Common frustrations:
1. Destructive Fasteners
One-way clips, welded seams, glued assemblies. Sometimes you have to break it.
2. Proprietary Components
Custom ASICs with no markings. Good luck figuring those out.
3. Miniaturization
Components so small you need a microscope. And steady hands.
4. Complexity
Modern electronics have thousands of components. Overwhelming.
5. Time
A thorough teardown takes hours or days. Worth it, but demanding.
The Teardown Mindset
More than a skill, teardowns are a way of thinking:
- Curiosity - What's inside? How does it work?
- Respect - Someone designed this, learn from them
- Humility - Your first design won't be this good
- Critique - What could be better?
- Application - How can I use this?
This mindset extends beyond hardware:
- Tear down software (read source code)
- Tear down businesses (study financials)
- Tear down writing (analyze structure)
- Tear down arguments (examine logic)
Systematic deconstruction is a superpower.
Your Turn
If you've never done a teardown, start simple:
- Find something broken (or cheap and expendable)
- Take photos before you start
- Disassemble carefully, keeping track of parts
- Try to understand how it works
- Attempt to reassemble (bonus points if it works after)
Then do it again. And again. You'll be amazed what you learn.
And if you document it, share it! The world needs more teardowns.
Conclusion
Every product is a frozen design decision. A snapshot of tradeoffs, constraints, and creativity.
Teardowns let you unfreeze those decisions. To see the thinking behind the thing. To learn from successes and failures.
For Thios, teardowns have been invaluable. They've shaped our designs, informed our cost targets, and taught us what works (and what doesn't).
If you're building hardware—or anything physical—make teardowns part of your practice.
You'll never look at products the same way again.
Resources:
P.S. - What's the most interesting thing you've ever taken apart? Tell me in the comments!