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The Printed Circuit Designer's Guide to... ™
Designing for Reality

by: Matt Stevenson

Creating a robust and manufacturable PCB design requires paying close attention to numerous details. There are many unwritten rules, best practice techniques, and design requirements that vary by manufacturer. In The Printed Circuit Designer’s Guide to… Designing for Reality, author Matt Stevenson reveals how these often-subtle factors enable designers to create realistic board designs that will take their skills from novice to advanced.

Based on the wisdom of 50 years of PCB manufacturing at Sunstone Circuits, this book is a must-have reference for designers understanding the PCB manufacturing process as it relates to their design. Designing for manufacturability requires understanding the production process fundamentals and factors within the process that often lead to variations in manufacturability, reliability, and cost of the board.



ISBN: 979-8-9856020-8-1

Matt Stevenson is the vice president of sales, marketing and operations for Sunstone Circuits. In his 26+ years in the printed circuit board industry, he has developed an extensive knowledge of PCB manufacturing. Previous roles include operational engineering, materials, quality, marketing and leading the business.

Matt has earned two Bachelor of Science degrees (chemistry and chemical engineering) from Colorado State University, as well as an MBA from Portland State University.

Matt’s articles and columns have been published in a number of trade journals focused on printed circuit board design and manufacturing. Outside of work, he enjoys time at the ball fields with his family, hiking, working on home projects, and relaxing.

American Standard Circuits (ASC) and Sunstone Circuits have joined forces to create a formidable entity in PCB manufacturing, leveraging over 50 years of combined industry expertise. This unified collaboration harnesses ASC's comprehensive solutions expertise and Sunstone's focus on rapid turnaround, top-quality PCBs, and unparalleled customer support.

Our commitment extends to providing a diverse range of PCB types customized for various industries, including military/aerospace, industrial, commercial, medical, telecommunications, consumer electronics, RF/microwave, and transportation sectors. ASC-Sunstone stands as a hub for excellence in PCB manufacturing, simplifying procurement while delivering top-notch products.

At the forefront of technology, our ongoing research and development in thermal management and embedded passive components enable us to meet the demands of ever-evolving computing devices. Our specialties encompass hybrid circuits, exotic materials, blind and buried vias, controlled impedance, and patented thermal management solutions.

Quality is our hallmark. ASC holds certifications such as AS9100 Rev. C, ISO 9001:2008, and MIL PRF 31032, reinforced by state-of-the-art process control systems. Rigorous SPC controls, automated optical inspection, metallographic cross-section, and electrical test facilities ensure we meet and exceed the high standards set by our customers.

We understand the urgency of timelines in the industry. ASC-Sunstone prides itself on quick-turn capabilities across all our manufacturing technologies. Our cutting-edge front-end engineering CAM systems and rapid-response manufacturing processes enable us to provide swift solutions for our customers.

For more information on our wide range of offerings and quick-turn options, visit www.ascsunstone.com. Together, ASC and Sunstone set a new standard of excellence in PCB manufacturing, offering unmatched expertise, support, and top-quality products across diverse industry sectors.

This book has been technically reviewed by the following experts:

Duane Benson

Director of Marketing, Screaming Circuits

Duane Benson is a technology journalist and consultant. He has 35+ years in the electronics design and manufacturing industry as a developer, executive, speaker and writer, including nearly 20 years as a driver in the quick-turn and on-demand electronics manufacturing industry. Duane has a [...]

Bob Tise

R&D Engineer, EMP Shield

With over 30 years of working with PCB design, library development and PCB fabrication, Bob Tise has worn several hats in the printed circuit board industry. He has worked as a contractor at several companies such as InFocus Systems, Intel, Hewlett-Packard, Credence Technologies and Cascade [...]

Chapter Summaries

  • Chapter 1

    Choosing a CAD Tool


    Choosing the right CAD tool is an important part of the designing for reality journey
  • Chapter 2

    Variations in the Manufacturing Process


    Forethought during design can help mitigate variation and physical challenges in the manufacturing process
  • Chapter 3

    Introduction to PCB Manufacturing


    A high-level view of the PCB production process
  • Chapter 4

    What CAM Can and Cannot Do


    A look at a few reasons CAM might change your design
  • Chapter 5

    Imaging


    How does the imaging process affect design considerations?
  • Chapter 6

    Wet Processing and Metallizing


    Additive and subtractive processes
  • Chapter 7

    Qualifying Your PCB Supplier


    Five key attributes of an optimal manufacturing partner
  • Chapter 8

    Advice for Designers


    The "art" of circuit board design

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Duane Benson Duane Benson is a technology journalist and consultant. He has 35+ years in the electronics design and manufacturing industry as a developer, executive, speaker and writer, including nearly 20 years as a driver in the quick-turn and on-demand electronics manufacturing industry. Duane has a recognized track record of making complex subjects easy to understand and of evaluating information from more than just the obvious perspective.

Bob Tise With over 30 years of working with PCB design, library development and PCB fabrication, Bob Tise has worn several hats in the printed circuit board industry. He has worked as a contractor at several companies such as InFocus Systems, Intel, Hewlett-Packard, Credence Technologies and Cascade Microtech. Over the years Bob has had occasion to help with development of some high-performance electronics and was witness to the very first projected picture on the wall by InFocus. Bob is an avid mountain bike rider and has been a member of the Mount Hood Ski Patrol for over 30 years. In his off time, you can also find him tinkering with old cars and trying his hand at woodworking.