The cost of not considering your thermal management early in the development process is more than money. Although the financial impact can be staggering, the consequences of an insufficient cooling solution include missed deadlines, product failures and recalls, costly redesign and rework, scrapped materials, safety concerns, and endless amounts of frustration.
The repercussions of a subpar cooling solution include unfavorable product reviews, lower reliability, shorter product lifetime, noise issues, higher maintenance costs, and overall poor product performance. Additionally, it does not allow for forward compatibility. A poor solution cannot move forward into next generation products, but an optimized solution makes that next generation more likely.
In short, it is important that you take the time and effort to optimize your cooling and include it early in your design process.