How many rounds of samples should I expect before something's actually production-ready?
Budget for at least three, a rough first sample to check the concept works, a refined second sample that fixes the obvious misses, and a pre-production (PP) sample that should be near-identical to what ships. If you're still rejecting samples after round four, the problem is usually your spec sheet, not the factory. Pay for every sample; free samples train you to accept mediocre ones.
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Makes the direct case for treating the pre-production sample as your last checkpoint before a batch you can't easily undo.