Case Study: PCB Design Flaws Affect Product Cost
December 3, 2024 | Matt Stevenson, ASC SunstoneEstimated reading time: 1 minute
In the rapidly evolving aerospace industry, precision and reliability are paramount. “AeroTech Solutions” (not the company’s real name), an aerospace company specializing in satellite technology, recently faced a significant challenge that tested its operational integrity: A flaw identified in the PCB design of its latest satellite model led to unexpected delays and cost overruns. This article explores the issues the company encountered, its collaboration with its PCB manufacturer to resolve these challenges, and the steps taken to ensure project success moving forward. The real cost to manufacture can be greatly affected at the PCB design level.
AeroTech Solutions has built a reputation for innovation and excellence in the aerospace technology market. With numerous successful satellite projects under its belt, the company was poised to launch its newest satellite designed for advanced communications and earth monitoring. However, during the final stages of production, the engineering team detected a flaw in the PCB design which was causing functional failures and putting the satellite’s operational functionality at risk.
The Issue: PCB Design Flaw
The PCB design flaw was identified during the final test stage of the prototype PCBA. Engineers kept finding assemblies that showed the flaw at various levels throughout the testing phases, and finally identified the root cause during final test. They discovered that the designer had overlooked critical routing on a very sensitive portion of the design. That created issues with the clean transfer of the signal and created isolated overheating. This led to delamination and jeopardized the satellite’s mission objectives.
To read the entire case study, which originally published in the November 2024 PCB007 Magazine, click here.
Testimonial
"Advertising in PCB007 Magazine has been a great way to showcase our bare board testers to the right audience. The I-Connect007 team makes the process smooth and professional. We’re proud to be featured in such a trusted publication."
Klaus Koziol - atgSuggested Items
Peters, Starteam, and Würth Elektronik Team Up For Digital Coating Technology
10/23/2025 | PetersUnder this heading, the PCB manufacturers Starteam and Würth Elektronik, along with Peters as inkjet coating supplier, have taken the initiative and worked together for months in trusting and target-oriented cooperation, to promote this innovative digital coating technology for solder resists and establish it on the market.
AI Triggers Next Paradigm Shift in PDN
10/23/2025 | Istvan Novak, SamtecArtificial intelligence (AI), together with machine learning (ML), is creating an unprecedented surge of computing and networking infrastructure needs. This, in turn, has dramatically increased the power consumption of computing and networking chips.
SEMICON Japan 2025 to Spotlight Sustainability in AI and Semiconductor Innovation
10/22/2025 | SEMISEMICON Japan 2025, the largest gathering of leaders from the microelectronics manufacturing supply chain in Japan, will bring together more than 1,200 exhibitors showcasing semiconductor solutions from December 17-19 at Tokyo Big Sight.
Zuken Announces ZIW Americas 2026 in Dallas
10/21/2025 | ZukenZuken USA, Inc., a global leader in electrical and electronic design automation, announced Zuken Innovation World (ZIW) Americas 2026, the company’s premier global conference dedicated to advancing the future of electrical and electronic product design. ZIW 2026 will be held June 9-11 in Dallas, Texas.
Keysight Completes Acquisition of Synopsys’ Optical Solutions Group and Ansys’ PowerArtist
10/17/2025 | Keysight Technologies, Inc.Keysight Technologies, Inc., announced the completion of its acquisitions of the Optical Solutions Group from Synopsys, Inc., and PowerArtist from Ansys, Inc.