A printed circuit board (PCB) powers the core of every electronic gadget. How it works is straightforward; the board (B) is printed (P) and circuits (C) are attached.
Board (B)
A non-conductive material, such as fibre or glass, is typically used for the board.
Printing (P)
The map that lays out where the circuits will go is printed on the board. Copper tracks are used in place of wires to conduct electricity between components.
Circuits (C)
Vias (holes) are drilled through the board, the electronic components are placed in the vias, and soldering attaches components to the board. This forms a circuit, the primary element that makes the gadget work.
Sounds simple enough, right?
Well, it isn’t.
A lot of work goes into printing a board; engineers design PCB layouts in different ways depending on desired outputs. One size does not fit all! Component placement is like putting together a high-tech puzzle that has thousands of tiny pieces. Design engineers are skilled at creating unique representations of a PCB layout from the same schematic. By using different placements for individual components and routing them in certain ways, they get electronically creative. And by creative, we mean they solve the puzzle by designing components in the best possible way to make the circuit most efficient—which saves time and money.
PCB design and manufacturing is more complex than it appears!
Complexities of circuit board design
The design process factors in how to avoid problems during the manufacturing phase. When orienting similar components, the engineer ensures they face in the same direction and that there’s enough room between components for routing and soldering components to the board.
PCB design flaws increase costs for both the electronics manufacturer and the designer. If the design needs modification and the designer has to step back to correct design flaws, it delays time-to-market. If a design flaw makes it to the manufacturing phase, that’s even worse—as the function will be compromised.
Challenges in DIY circuit board design:
The complexity of design makes PCB failure a real possibility. PCB designers—especially DIY designers—face these challenges:
Inaccurate PCB component layout:
Layout inconsistencies such as insufficient width for copper traces, less space between components, incorrect placement of decoupling capacitors, and incorrect wireless antenna location cause problems.
Incorrect landing patterns:
When components not included in digital libraries of PCB design software are used, manually-drawn landing patterns are prone to errors.
Other problems:
Incorrect measurements, drilling errors, and over-etching are other design challenges. These flaws affect the functionality of the finished product. That’s why it is crucial to engage an experienced PCB design and manufacturing company for your circuit board design.
Benefits of working with a reputable PCB manufacturer:
PCB design is the most time-consuming phase of the PCB production lifecycle. Once the circuit board has been laid out and tested, the production phase is quicker, easier, and affordable. It makes sense not to lowball your options when it comes to circuit board design. Flaws in the design process lead to higher costs due to design modifications, longer time-to-market, problems in the reliability of the device, and customer dissatisfaction with glitchy end-products.
Look for an electronics manufacturing company that designs high-quality circuit boards, pays attention to detail, and uses high-quality components. Avoid manufacturers that outsource parts of the design and manufacturing process to cheaper vendors (who use cheaper parts).
Choose a manufacturer that ticks all the boxes:
Experienced manufacturers:
Does the company have a strong reputation and extensive experience in electronics manufacturing? Manufacturers who have been around in the industry for several years are a safer bet. Not only do they have years of prior experience, but they also have a reputation to uphold, which means they apply best practices in design and production. Well-reputed companies take care to produce components of the highest quality.
Design & technology capabilities:
Choose a company that demonstrates the expertise required to produce a winning product. A company that has a wide range of services, starting with design and pre-manufacturing, post-manufacturing, as well as PCB testing services, provides the most comprehensive support. This, in turn, ensures optimal cost, safety, and reliability of your end-products. Check to see if the manufacturer uses the latest and most advanced equipment and tools to give your product a competitive advantage.
DFM best practices:
Choose a PCB design company that follows best practices in DFM (Design for Manufacturability). DFM a process that involves inspecting a circuit board layout to minimize any problems that happen during fabrication and assembly. When this process is followed, the end-product functions reliably. The unique aspect of the DFM process is that it looks at how the circuit board will potentially break, rather than look at how the circuit board will work.
Certified companies:
Certifications are proof that the company follows industry-approved protocols and accepted standards in design and production. Companies with certifications such as IEC6061-1 will follow optimal safety and quality protocols that ensure the durability and reliability of the end-product.
Finally, you may also want to check if the company is compliant with any green laws regarding hazardous substances used in production. This not only ensures that your product meets environmental regulations, but it also gives you bonus points from customers who are increasingly choosing eco-friendly products.
Bad design is something every product company wants to stay away from; design flaws can be catastrophic for a company. Not only do they increase the cost of production, but they also delay the release of the product to market. When different vendors handle design, prototyping, and production, communication gaps and lack of coordination lead to design flaws slipping through the testing process.
Choose a company like MIS Electronics that offers comprehensive circuit board design, production, and testing services. Tell us about your requirements and get a no-obligation quote!