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Fresh PCB Concepts: Resilience and Renewal in Domestic PCB Manufacturing

As veterans of PCB manufacturing, we have spent much of our careers walking factory floors, examining copper circuits under microscopes, and troubleshooting plating lines when they go awry at 2 a.m. We can say with confidence that PCBs are the unsung heroes of modern life. They’re in everything, from toothbrushes and thermostats to satellites and defense systems.

As the electronics industry navigates geopolitical uncertainty and increased demand for supply chain diversity, there has never been a better time to take a close look at U.S. PCB manufacturing. What we see is not simply a story of decline. It embodies resilience, renewal, and opportunity.

A Brief History: From Powerhouse to Niche Player
For much of the 20th century, the United States was a global leader in PCB manufacturing. American shops powered breakthroughs in aerospace, defense, telecommunications, and computing. Silicon Valley relied on a thriving domestic PCB base to turn bold ideas into functional hardware.

But the 1990s brought globalization, and with it, a dramatic shift. High-volume, cost-sensitive production moved to Asia, where economies of scale prevailed. By 1998, the U.S. produced about 30% of the world’s PCBs; today that figure is under 4%. We lost more than capacity. We lost skills, infrastructure, and the pipeline of new talent entering the field.

Yet, American PCB shops didn’t disappear. They evolved. Many pivoted to serve sectors—aerospace, defense, medical devices, and advanced automotive—where failure is not an option. In these industries, quality, trust, and speed matter far more than pennies per square inch.

Today’s Landscape: Challenges and Change
A U.S. PCB shop is a blend of history and innovation. Some machines have been running for decades, operated by technicians with 30 or 40 years of hands-on knowledge. Alongside them are modern direct imaging systems, automated optical inspection, and high-speed drilling equipment.

But the challenges are real. Rebuilding capacity requires equipment combined with an ecosystem of laminate suppliers, plating chemistries, drill bit vendors, and test houses. It also takes people. Many veterans are nearing retirement, and the knowledge they carry—recognizing a delamination risk by touch, diagnosing a plating line by sound—cannot be easily replaced by manuals or software.

At the same time, tariffs, supply chain disruptions, and national security concerns have accelerated the conversation around reshoring. Legislation like the CHIPS and Science Act (2022) and the proposed PCBs for America Act represent meaningful steps toward restoring domestic strength. The Department of Defense has also prioritized trusted U.S.-based suppliers for high-reliability programs.

A Fresh Perspective: Seeing the Factory for the First Time
Sometimes the best way to understand an industry’s challenges and promise is through the eyes of someone seeing it for the first time. Ethan Scherer, quote engineer at NCAB Group USA, recently toured two PCB factories in the Chicago area and shared his experience with us. He has been working on fabrication drawings since 2022, but last month was his first time setting foot in a PCB factory. We asked Ethan to share some of his thoughts about the tours.

Ethan, this was your first time inside a PCB factory. How did it strike you?
Ethan Scherer: It simplified the process in my mind. From the outside, PCB manufacturing can seem daunting. But seeing the stackup, drilling, and plating firsthand made it much more tangible.

What surprised you most?
How the stackup is created using tooling pins before trimming excess material. I also didn’t expect to see multiple panels pressed and processed together. The plating lab was impressive—tracking bath chemistry in real time and linking data back to quality issues for troubleshooting.

What else stood out?
The contrast between facilities. One was chaotic, with boards wheeled around on carts; the newer one flowed efficiently down a single hallway. And yes, the smell of ammonia in the older shop caught me off guard.

How will this experience affect your work?
It gave me a deeper appreciation for specifications. Now, when I look at a stackup, I can visualize the materials and processes happening on the floor. It’s easier to understand why the details matter.

Ethan’s reflections highlight an important truth: PCB manufacturing is best understood hands-on. For the next generation of engineers, opportunities like these are invaluable. A special thank you to Alpha Circuit for their partnership and extending the opportunity for these in-depth tours.

Passing the Torch: Mentorship and Education
PCB manufacturing is a craft as much as a science, and its survival depends on passing down knowledge. At NCAB and across the industry, younger engineers are being paired with seasoned process experts to learn not just how to design a Gerber file, but how plating throw works, why resin flow matters, and how glass weave skew affects performance. These lessons mean fewer redesign cycles, better manufacturability, and smarter innovation.

Industry organizations are also stepping up. The Electronics Foundation is reaching students earlier, while universities like Cal Poly are teaching design-for-manufacturing hands-on. Programs like these are helping the next generation see that PCB manufacturing is essential, challenging, and deeply rewarding.

Looking Forward: Innovation Over Volume
The future of U.S. PCB manufacturing won’t be about competing with Asia on volume. That battle was decided long ago. Instead, America can lead in precision, speed, and innovation.

Semi-additive processes are enabling ultra-fine line widths. Embedded components are integrating functionality directly into substrates. Rigid-flex hybrids are delivering reliability in tight, high-performance spaces. Advanced HDI and additive PCB techniques are already reshaping what’s possible.

Beyond the machines and processes, there’s pride in seeing a design become a functioning board, and in knowing that a spacecraft, medical device, or defense system is powered by technology built here at home.

Conclusion: A Circuit Worth Re-spinning
Yes, globalization reshaped the industry. But America’s PCB story is one of resilience. We are not just looking back at what was lost. We are building forward, passing down knowledge, investing in people, and embracing innovation.

Domestic PCB manufacturing will not look like it did in the 1980s—and it shouldn’t. Its strength lies in being the trusted partner for industries where performance, reliability, and security matter most.

The only certainty is change. But if we invest in skills, infrastructure, and collaboration, the future of U.S. PCB manufacturing will be bright. And that’s a circuit worth re-spinning.

Team NCAB is Jeffrey Beauchamp, Ramon Roche, Michael Marshall, and Ryan Miller.