Before you get too far with your brain wracking, spend some time minimizing the count of different components.
Uh-oh, one of those unexpected problems has surfaced.1000 x $100 average to make good. Oh sh|t, there goes your $100KA lot of work to get nothing back - except a dented reputation.Be careful.
Your problems will probably get more expensive in the long run. Is your power supply UL certified and is it plugged into your device or is it part of your device. If part of your device, the the WHOLE device must be UL certified. I had a customer that needed UL certification. We had to do a production run of 400 devices with serial numbers. Then the lab doing the certification selected a random number of serial numbers for testing.Since your device also includes an oscillator with 400kHz or more frequency, you will also need FCC certification by a certified lab. And if you make future software or hardware changes the FCC certification must be repeated. Welcome to the real world!Paul
DESIGN FLAW - Not at all,
UL certification could care less if the components in your project are UL certified or not. It is YOUR product that must be lab certified.
Seems like it is time for you to pay personal visits to businesses that specialize in manufacturing products for their customers, like my former company did.
I have a family member who is the VP of a small local manufacturing and engineering services firm. Perhaps my best immediate option?