-
- News
- Books
Featured Books
- pcb007 Magazine
Latest Issues
Current IssueSales: From Pitch to PO
From the first cold call to finally receiving that first purchase order, the July PCB007 Magazine breaks down some critical parts of the sales stack. To up your sales game, read on!
The Hole Truth: Via Integrity in an HDI World
From the drilled hole to registration across multiple sequential lamination cycles, to the quality of your copper plating, via reliability in an HDI world is becoming an ever-greater challenge. This month we look at “The Hole Truth,” from creating the “perfect” via to how you can assure via quality and reliability, the first time, every time.
In Pursuit of Perfection: Defect Reduction
For bare PCB board fabrication, defect reduction is a critical aspect of a company's bottom line profitability. In this issue, we examine how imaging, etching, and plating processes can provide information and insight into reducing defects and increasing yields.
- Articles
- Columns
- Links
- Media kit
||| MENU - pcb007 Magazine
Hidden (and Obvious) Design Mishaps With Big Cost Impacts
August 14, 2024 | Jen Kolar, Monsoon SolutionsEstimated reading time: 2 minutes

At Monsoon Solutions, we provide PCB layout services for the full lifecycle of products, from one-off prototypes to items manufactured in production volume. We also manage manufacturing and assembly for prototype and smaller production runs for both customer-produced and in-house layouts. As a result, we see various manufacturing data packages and work with many different manufacturers. I asked our PCB design engineers and program managers to share the cost adders and cost savers that designers can affect, and it was interesting to see that in addition to more technical responses, some of the biggest culprits were rather simple.
Fabrication Note Errors
Starting with PCB fabrication, one of the most obvious and simplest cost adders is incorrect or missing fabrication notes. As designers, we all like to have a starting point for a layout rather than having to start from scratch, and that often means starting from a similar board, which comes with existing fabrication notes. As a service bureau, we also often work on revisions of designs, and thus we inherit fabrication notes from the previous design. A common mistake I see from designers is when they leave notes the new designer doesn’t understand or know if they are required. I will often see them ask the customer about the notes, and it’s not uncommon for the customer to not know if they apply either. Rather than removing them, they commonly remain “just to be safe.” This often leads to extra processes like via fill, planarize, and plate. It may lead to building to Class 3 vs. Class 2 or extra testing and paperwork requirements. It may lead to adding hard gold vs. just ENIG. It may lead to ordering more exotic materials where standard FR-4 was fine. It also can lead to back-and-forth DFM questions as the fabricator must confirm what does or doesn’t apply, and with which offshore vendors can mean delays of multiple days.
Similarly, if there are no fabrication notes, the fabrication vendor is left guessing and may choose processes or materials that are more expensive or not absolutely needed, or they may miss important aspects of the design, like controlled impedances or that a specific thickness is needed for edge connectors. Make sure to review your notes for clarity and correctness before sending them to the fabrication shop. If you are unsure how to specify your requirements, talk to your fabricator.
To read the entire article, which originally appeared in the August 2024 Design007 Magazine, click here.
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
Direct Metallization: A Sustainable Shift in PCB Fabrication
07/31/2025 | Jim Watkowski, Harry Yang, and Mark Edwards, MacDermid Alpha Electronics SolutionsThe global electronics industry is undergoing a significant transformation, driven by the need for more resilient supply chains and environmentally sustainable manufacturing practices. Printed circuit boards (PCBs), the backbone of interconnection for electronic devices, are at the center of this shift. Traditionally, PCB fabrication has relied heavily on electroless copper, a process that, while effective, is resource-intensive and environmentally hazardous. In response, many manufacturers are turning to direct metallization technologies as a cleaner, more efficient alternative.
From Factory Floor to ‘The Component Store’
07/25/2025 | Marcy LaRont, I-Connect007Daniel Beauvois began his career in PCB manufacturing 15 years ago with zero industry experience—just a willingness to learn. Daniel immersed himself in every step of circuit board production, from hanging out on the factory floor to giving plant tours. Now, as founder of The Component Store, he’s an independent sales rep known for integrity, persistence, and deep technical knowledge. In this interview, Daniel reflects on his journey, the realities of being an outside rep, and what it takes to earn—and keep—a customer’s trust in an ever-evolving electronics industry.
Elementary Mr. Watson: Closing the Gap Between Design and Manufacturing
07/23/2025 | John Watson -- Column: Elementary, Mr. WatsonModern PCB designers are not merely engineers or technicians. I believe that PCB design, at its core, is an art form, and modern PCB designers should be considered artists. Beyond the technical calculations and engineering rules lies a creative process that involves vision, balance, and a passion for what we do. Like any artist who works with brush and canvas or chisel and stone, a PCB designer shapes invisible pathways that bring ideas to life. Each trace, layer, and component placement reflects thoughtful decisions that blend form, fit, and function.
Designers Notebook: Basic PCB Planning Criteria—Establishing Design Constraints
07/22/2025 | Vern Solberg -- Column: Designer's NotebookPrinted circuit board development flows more smoothly when all critical issues are predefined and understood from the start. As a basic planning strategy, the designer must first consider the product performance criteria, then determine the specific industry standards or specifications that the product must meet. Planning also includes a review of all significant issues that may affect the product’s manufacture, performance, reliability, overall quality, and safety.
Trump Copper Tariffs Spark Concern
07/10/2025 | I-Connect007 Editorial TeamPresident Donald Trump stated on July 8 that he plans to impose a 50% tariff on copper imports, sparking concern in a global industry whose output is critical to electric vehicles, military hardware, semiconductors, and a wide range of consumer goods. According to Yahoo Finance, copper futures climbed over 2% following tariff confirmation.