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Beyond the Rulebook
What happens when the rule book is no longer useful, or worse, was never written in the first place? In today’s fast-moving electronics landscape, we’re increasingly asked to design and build what has no precedent, no proven path, and no tidy checklist to follow. This is where “Design for Invention” begins.
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From the growing role of AI in design tools to the challenge of managing cumulative tolerances, these articles in this issue examine the technical details, design choices, and manufacturing considerations that determine whether a board works as intended.
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I-Connect007 Magazine previews APEX EXPO 2026, covering everything from the show floor to the technical conference. For PCB designers, we move past the dreaded auto-router and spotlight AI design tools that actually matter.
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Altium ActiveRoute Debuts at PCB West: Routes Under One Second Per Connection
October 20, 2016 | Judy Warner, I-Connect007Estimated reading time: 6 minutes
While at PCB West in Santa Clara in mid-September, I had the chance to sit down with Charles Pfeil of Altium and learn more about their exciting new tool, ActiveRoute, that was introduced and demonstrated in their booth during PCB West 2016. I also learned a bit about Pfeil, who is a living history lesson in PCB design.
Judy Warner: Charles, nice to see you again. You have been very busy here at PCB West, doing hourly demonstrations of your new product, ActiveRoute, in the Altium booth. Please tell us a little bit about what you're demonstrating here at the show.
Charles Pfeil: ActiveRoute is a tool that helps designers do their interactive routing. It's not an automatic router, although it has very high levels of automation. The intent is to provide the designer with a way to interactively route, following all the rules, constraints, and restrictions, under their control so they can tell the routing technology where to route, what layer to route, and then they will route it very, very quickly. It generally routes in less than one second per connection.
Warner: What is the standard routing time?
Pfeil: I've actually run some tests and some competitions, and for the best designers, when we're talking about a 100–200 nets, the average is about one minute, and I'd say for the average designer it is closer to three minutes.
Warner: Impressive. So this speeds things up dramatically, up but still gives designers the control? I know with autorouting, designers lose some of that control, which they don’t like.
Pfeil: Exactly. Autorouting has a stigma, right? And rightly so [laughs]. The problem with autorouting is that it will put in way too many vias, and a typical statement I hear is, “It will take me more time to clean it up than if I had just routed it by myself in the beginning.” Although the autorouter itself would be very fast, the time it takes to clean it up and the pain to clean it up isn't worth it, so they'd rather route it interactively. This tool works as an interactive tool. You can take a small number of nets or a large number of nets, route them, and you have tools for guiding where it's supposed to be routed. The intent is to make the designer more productive, not just put it into a route engine and have it work on it for a while, and then give you back the results.
Warner: It sounds like it will speed up the design, keep the control, but give you the advantage of some of the speed of an autorouter.
Pfeil: The speed and the quality are really important. Designers like me are OCD, but quality is something that isn't just, "It looks pretty." It's about being efficient, and it's about, "I want the least number of segments, I don't want extra meandering, and I want it to be routed in groups. I want things spaced out at times." This is what quality is about. Sometimes quality is misinterpreted as pretty, but it's really about having efficient routing that is easy to edit in the future. The OCD part of us will make things symmetrical and evenly spaced, even when it's not necessary, but that's the way designers are. If you give a designer a tool to help with routing, they won't use it if they have to spend a lot of time cleaning up. Cleaning up means, “It didn't do what I would've done.” That's the hard part: producing the results in which a designer would say, "Yeah, that's good. I'm going to go to the next step. I don't have to adjust all these things."
Warner: Will this tool be an add-on or will it be integrated into Altium Designer?
Pfeil: It's included with Altium Designer. It's part of the base product.
Warner: Is that starting right now or on the next release?
Pfeil: It's starting with Release 17.0 which will be out before the end of this year.
Warner: Do you think that having this feature may help you sell more licenses?
Pfeil: In the end, it's the bottom line, right? It's one of many things that are new in 17.0. We did a lot of work on making the user interface easier. Our Vault capability has been enhanced significantly. We're continuing to improve the tool in whatever ways we can. I've been focused on the routing side, and really trying to make a tool that designers will want to use and become more productive.
Warner: You've been giving demos every hour here. Tell us a little bit about the response from the designers that you've been talking with.
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Testimonial
"In a year when every marketing dollar mattered, I chose to keep I-Connect007 in our 2025 plan. Their commitment to high-quality, insightful content aligns with Koh Young’s values and helps readers navigate a changing industry. "
Brent Fischthal - Koh YoungSuggested Items
When Quality Is Personal: The Human Stakes Behind Electronics Reliability
05/06/2026 | Kelly DackIn electronics manufacturing, quality is often discussed in terms of specifications, standards, and process controls, but as industry veteran Doug Pauls reminds us, the stakes are far more human. In this conversation, Doug, a recipient of the Global Electronics Association’s Hall of Fame Award, draws on more than four decades of experience to illuminate the real-world consequences of reliability, where even a single defect can carry profound implications. He brings into sharp focus why quality isn’t just a metric, but a responsibility shared by everyone on the manufacturing floor.
PCBAA, AAM Take on the Fight to Rebuild U.S. Manufacturing in New Documentary
05/05/2026 | Marcy LaRont, I-Connect007Throughout most of the 20th century, manufacturing was central to the American Dream of providing stable jobs and pathways to upward mobility. Today, more than 80% of global electronics manufacturing capacity resides in China and greater Asia, raising serious concerns about supply chain resilience and national security.
India’s Vasantha Advanced Systems: EMS Success for 30 Years
04/22/2026 | Marcy LaRont, I-Connect007Based in one of India’s premier manufacturing regions, Vasantha Advanced Systems is an EMS provider that has built a reputation for quality, reliability, and long-term customer partnerships, earning repeated recognition from the Indian government through its National MSME Awards. Now, with a full spectrum of capabilities spanning PCB assembly, box build, and wire harness, and a workforce of more than 500, Vasantha is expanding its presence into the U.S. market. At APEX EXPO, I met Dr. Chidambaranathan and learned how this rising global player is positioning itself to meet the evolving needs of North American customers.
April Issue of I-Connect007 Magazine: Beyond the Rulebook
04/14/2026 | I-Connect007 Editorial TeamIn this month’s I-Connect007 Magazine, we asked PCB designers, fabricators, and suppliers what it really means to operate without a rulebook. Their perspectives vary, especially between seasoned designers and experienced fabricators, but a common thread emerges: progress depends on pushing boundaries and finding a way forward, even when the path isn’t clear. In many ways, this mindset has always been part of what we do, whether we’ve called it that or not.
Defense Speak Interpreted: Hypersonics Report Back After Six Years of Silence
04/07/2026 | Dennis Fritz -- Column: Defense Speak InterpretedIt’s been six years since my Defense Speaks column about hypersonic weapons. Back then, these weapons were the most sought-after technology as there was little defense for them. They were the cornerstone of the “strike any location on earth within one hour” scenario. Of course, the war in Ukraine, and now the action in Iran, have grabbed the weapons headlines, but hypersonics still play a role and development continues. Here is the update.