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RF PCB Design: The Devil’s in the Details

Altium’s John Watson is a longtime designer and design instructor, not to mention a Design007 columnist. He’s been dealing with RF issues for years; his previous employer, Legrand, is one of the pioneers in smart lighting and data center solutions. John discusses the differences between designing RF and “typical” PCBs, how to avoid the missteps and miscues that can bedevil new RF designers, and why the tiniest details can make or break an RF design.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

How was your week? We’ve been pretty busy ourselves, bringing you coverage of the SMTA Expo & Tech Forum in Boise, Idaho. Tabletops shows like this offer a great value during the spring, in between the bigger shows like IPC APEX EXPO and SMTA International. In fact, SMTA schedules approximately 30 regional shows around the United States and abroad.

DFM Analysis for Flex and Rigid-flex Design, Part 1

Flex and rigid-flex PCB constructions are not new concepts. It has become commonplace as engineers look for alternative circuit packaging for ever-shrinking electronic products. A flat, one-sheet schematic for a straight ribbon cable is analogous to its physical flat substrate. A flat, multi-sheet schematic that details circuitry for a rigid-flex design bears little visual resemblance to its three-dimensional, variable material rigid-flex assembly. However, in both schematic examples, schematic-based analysis tools are applied equally. This same truth also applies to common FR-4-based two-layer or multilayer PCBs.

Design for Cost in Real-time

When do you first start thinking about the selling price of your new product? It’s impossible to avoid the question of what the price will be. The worst answer is: “I don’t know, let’s see after the first samples.” Let’s say the product’s selling price is $49; then the manufacturing cost will be $20. During each design change, the manufacturing cost should be recalculated to make sure the product is still competitive. This means you should involve people from both the development and cost calculation teams. This circle will be repeated until the final design is released, and the final calculation is done.

DFM 101: Final Finish Design Guidelines

One of the biggest challenges facing PCB designers is not understanding the cost drivers in the PCB manufacturing process. There are many design considerations that need to be factored into any decision of which final finish to select for a particular application. We will cover these in this final installment of final finish DFM. Understanding the cost drivers in PCB fabrication and early engagement between the designer and the fabricator are crucial elements that lead to cost-effective design success.

Better Engineering Through Artificial Intelligence

At DesignCon 2023, I spoke with Cadence Design Systems’ Brad Griffin about artificial intelligence and machine learning as engineering aids for signal and power integrity optimization. Brad makes the case that artificial intelligence methods, when added to optimizing tools in the design flow, can help engineers to evaluate a larger number of potential solutions, and zero in on more highly optimized solutions than they may have found on their own.

IPC Design Competition Wrap-up

The IPC Design Competition took place during IPC APEX EXPO 2023, with five finalists competing—a far cry from the original 49 entries last fall. After the competition was over, we spoke with Kris Moyer, the IPC instructor who created the design used in the competition and served as a design advisor and judge for the event. We asked Kris to give us a quick wrap-up of the competition, as well as his thoughts on this year’s design, which none of the finalists completed.

Embedding Know-how Into Automation

Michael Ford, senior director of emerging industry strategy for Aegis Software, speaks with Barry Matties on the topic of tribal knowledge, its pros and cons, and its role in our industry. While it may be useful if your team never changes, the inevitability of a person’s career progression means they take their knowledge with them. Michael brings his nuanced perspective to the conversation.

Savita Ganjigatti: The Spark of Innovation

Savita Ganjigatti, vice president of engineering at Sienna ECAD Technologies, shares how her well-timed suggestion sparked the worldwide phenomenon that is the IPC PCB Design Competition, as well as how well-informed leaders are uniquely positioned to shape our industry’s future. Savita’s recipe for success? Work hard, read widely, and reframe problems as exciting possibilities for innovation.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

Texans like to say that everything is bigger in Texas. That certainly seems to be the case for the SMTA Dallas Expo & Tech Forum. Publisher Barry Matties and I attended SMTA Dallas on Tuesday, and the tabletop show has now grown to 100 exhibitors, up from 92 vendors last year. It’s become more than a local or regional show, with some exhibitors flying in from Silicon Valley and the East Coast.

Material Matters and Tribal Knowledge

At a recent IPC Laminate/Prepreg Materials Subcommittee meeting, I made two observations: It was very well-chaired and managed, and despite a full attendance of very knowledgeable materials experts, none could remember the rationale for several of the specification sheet descriptions—slash sheets—that comprise IPC-4101E, “Specification for Base Materials for Rigid and Multilayer Printed Boards.”

Tips and Tricks in Today’s Designs

Filbert Arzola of Raytheon Intelligence & Space taught a Professional Development course at IPC APEX EXPO on general design practices. During a break, Filbert spoke with Kelly Dack about some of today’s design strategies and how designers are reacting to them. What matters most?

True Experts Can Cite Their Sources

We’ve heard a lot lately about the need to identify tribal knowledge within our organizations. How do you know whether an “expert” is sharing documented knowledge or it’s just something they learned at their first job during the Carter administration? We asked IPC design instructor Kris Moyer to explain his process for separating the wheat from the chaff, so to speak, in design knowledge. As he points out, a true expert will not be afraid to cite the sources and data sets behind their arguments.

Optimizing Communication Between Fabricators and Designers

During DesignCon, I spoke with James Hofer from Accurate Circuit Engineering about some of his customers' biggest challenges. We discussed various ways to increase the level—and quality—of communication between designers and fabricators. James also offered some interesting observations about bridging the gap between designer and fabricator. How often do you communicate with your fabricator?

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

The captive shop used to be the rule, not the exception. Until outsourcing caught on, that is. North American captive shops went the way of the dodo bird, and the PCB market hasn’t been the same since. Even R&D went out the window, or offshore, if you want to be technical about it. But Schweitzer Engineering Laboratories (SEL) is something of a wild card. The company recently opened a new captive facility in Idaho, and the industry is paying close attention.

Sarah Czaplewski-Campbell: Ready to Take Flight

Sarah Czaplewski-Campbell, a materials/product development engineer at IBM, shares her experiences as a young professional who has benefited from the guidance of seasoned mentors alongside her own unflagging drive to expand her industry knowledge. She offers poignant advice for prospective professionals, urging them to assertively seek out advice and experiences that will help them progress in their careers.

Runner-up Discusses IPC Design Competition

PCB designer Adam Thorvaldson of Innovex was a finalist in this year’s IPC Design Competition at IPC APEX EXPO. He came in second place in this final heat, which is quite a feat, considering that the contest started last fall with 49 contestants from around the globe. We asked Adam to share his thoughts on the competition, what it means to be one of the winners, and any ideas about improving the contest for 2024 in Anaheim.

ICT Seminar 2023 Review: Energy, Thermals, and Assistive Technology

Widely believed to be the traditional Centre of England, Meriden was a popular venue for a gathering of the UK printed circuit community this month. They braved the forecast of heavy snow for the Institute of Circuit Technology’s annual general meeting to learn about current developments and challenges in a thought-provoking technical seminar and to network with industry peers and contemporaries. Thankfully, the forecasted heavy snowfall did not reach Meriden until after the event; we only had a few flurries, although the weather caused considerable disruption elsewhere in the country.

IPC APEX EXPO 2023 Special Session: Advanced Packaging

The IPC APEX EXPO Special Session on Advanced Packaging this year attracted enormous interest, with Conference Room 2 at capacity long before the session began. Even with lots of extra seats squeezed around the edges, the session was standing room only for the just-in-time arrivals. IPC Chief Technology Officer Matt Kelly opened proceedings by introducing a distinguished panel of experts: Jan Vardaman, president and founder of TechSearch International; Sam Salama, CEO of Hyperion Technology; Matt Neely, director of process engineering at TTM Technologies; and Jim Fuller, VP of engineering technology at Sanmina.

With Tribal Knowledge, Trust but Verify

Tamara Jovanovic is a design engineer with Happiest Baby, a manufacturer of smart baby beds that alert parents if the infant needs attention and soothes the baby back to sleep. She also recently completed her master’s degree in electrical engineering by studying around her work schedule. Since Tamara has been absorbing new information from the halls of academia and her workplace, we asked for her thoughts on differentiating between tribal knowledge and documented fact. Is tribal knowledge a friend, foe, or a little of both?

Thomas Marktscheffel: Collaboratively Revitalizing the Industry

Thomas Marktscheffel, director of product management software solutions at ASMPT GmbH & Co. KG, reflects on the evolution of industry-wide standards and how his multidisciplinary approach to the development of CFX has been crucial to its success. With the advent of digitalization, cultivating a collaborative spirit is now more than ever an essential component of standards development. Patty Goldman recently spoke with Thomas about what this award mean to him

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

I try to not talk about the weather in this space, but this week I feel compelled. I’m based in the Pacific Northwest, and we’re relatively used to it being wet and rainy. But just south of us in California, the state has gone from what I read has been called the driest period in the West in the past 1,200 years to a right proper drenching. This week’s news cycle felt like one of those California-style “atmospheric rivers.” There was so much worthy reporting worthy that I was a bit overwhelmed in making my final selections. Suffice it to say that, this week, there is quite a bit of news that’s worth your time to read.

Shrinking Silicon, Growing Signal Integrity Challenges

What happens when die sizes shrink? As IPC design instructor Kris Moyer explains, quite a bit. Shrinking silicon can mean rising signal speed and rise times, and traditional PCB designers may find themselves dealing with problems formerly only seen by RF engineers. We asked Kris to discuss the pros and cons of silicon shrinkage and some of the techniques and trade-offs that PCB designers and design engineers need to understand as they find themselves entering the RF arena.

DFM 101: Final Finishes—OSP

One of the biggest challenges facing PCB designers is not understanding the cost drivers in the PCB manufacturing process. The next final finishes to discuss in this series is OSP. As with all surface finishes there are pros and cons with the decision of which to use. It is a combination of application, cost, and the properties of the finish. OSP is RoHS-compliant as there is zero lead content in the finish.

Are You Offering Options in Your Bill of Materials?

In this interview, Saline Lectronics (an Emerald EMS company) President Jason Sciberras talks about PCB designers offering packaging options in the bill of materials. As Jason explains, mil/aero manufacturers like Saline can’t make many changes to a design without getting recertified, so including approved packaging options in the BOM from the start is a great way to go. Are you offering options in your BOM?

Meet Henry Crandall: New IPC Student Board Member

Barry Matties sits down with Henry Crandall, the newly minted Student Board Member on the IPC Board of Directors, to talk about how Henry became the first PhD student in electrical engineering in his family, as well as how his role on the IPC Board will allow him to represent the voices of students and young professionals interested in shaping the future of both IPC and the industry.

A Week-long Industry Extravaganza

We were back in San Diego, maybe for a “long vacation,” as IPC APEX EXPO is in Anaheim next year. Before we get to Anaheim, though, let’s talk about the show: It was a great week. I spent Sunday and Monday visiting some excellent Professional Development courses. As you know, this is a fast-changing industry, and we have to keep learning to stay ahead. On Monday, I attended the Microvia Weak Interface/Reliability subcommittee, and on Tuesday, the Ultra-HDI Technology Committee.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

It’s been a busy week in our industry. We have a duke’s mixture of news and columns in this week’s Editor’s Choice, starting off with some good news for the American electronics manufacturing industry. In his State of the Union speech, President Biden signaled his support for the CHIPS Act and the U.S. electronics industry, and he promised that Washington would put its money where its mouth is this time. Is it going to happen? Don’t bet the rent money.

Shrinking Silicon, EMI, and SI

Dr. Todd Hubing is a longtime EMC instructor, president of LearnEMC, and a professor emeritus of the Electrical and Computer Engineering program at Clemson University. I asked Todd to discuss the challenges that shrinking silicon can present for traditional PCB designers, as well as the opportunities and benefits of smaller chip features.

Real Time with... IPC APEX EXPO 2023: IPC Offers Free Training Courses

Guest editor Hannah Nelson speaks with IPC’s David Hernandez about new benefits IPC members can expect in its training programs. These complimentary courses will help workforce development and companies to reduce training costs and standardize training across their organizations.

A First Look at IPC-CFX Box for Legacy Equipment

Although the prevalence of IPC-CFX in the electronics manufacturing industry has increased since the standard’s launch in spring 2019, the committee responsible for the standard has recognized legacy equipment in the field as a significant barrier to widespread industry adoption. To address this, an A-Team under the IPC-CFX Standard Task Group spent the past year working on a project that provides simple, readily available IPC-CFX hardware with supporting SDK that can act as an IPC-CFX endpoint for existing legacy equipment.

Alpha Takes the Greenfield Route

Alpha Circuit is a PCB fabricator located in Elmhurst, Illinois. Given that the launch of a new PCB fab is a rare occasion these days, we caught up with the senior team—Prashant Patel, president and CEO; Steve Smith, general manager; Steve Ryan, sales and direct support—guiding the buildout of Alpha Circuit’s brand new 44,000 square foot facility. They discuss what goes into equipment selection and line design, and the timing couldn’t have been better. At press time, the new facility was on schedule for test production by the end of January 2023.

A Post-show Marketing Plan

After you’ve exhibited at a trade show, then the work really begins. Where do you begin? How do you best capitalize on the leads and other contacts you’ve made? We asked Kiki Shimomae, sales and marketing coordinator for Taiyo, to discuss her pre- and post-show plans for a show like IPC APEX EXPO, and the importance of staying visible on social media.

EIPC Winter Conference 2023, Day 2 Review

Day 2 of the EIPC Winter Conference at the Groupama Stadium in the Décines-Charpieu region of the Metropolis of Lyon in eastern France included a privileged visit to the Bugey Nuclear Power Plant for those who were registered and passed their security clearance. Such was the interest that the party was split into morning and afternoon groups. EIPC board member Martyn Gaudion, CEO of Polar Instruments, made a fine job of moderating Session 6 twice over.

Another Successful STEM Outreach

The IPC Education Foundation (IPCEF) hosted its annual STEM Outreach Event over the course of two days at IPC APEX EXPO 2023 in San Diego, accommodating more than 550 students on Wednesday, Jan. 25 and Thursday, Jan. 26. This was IPCEF’s largest event to date. The event created awareness of the many careers available in the electronics manufacturing industry and helped future talent engage and connect with industry professionals.

Coreen Blaylock: Opening Doors for New Professionals

Coreen Blaylock, recipient of the IPC Excellence in Education Award, is project management and ping operations at Lockheed Martin. She shares her unconventional introduction to the industry and how her work in STEM education and building industry partnerships has been instrumental in reinvigorating the manufacturing workforce. Lockheed Martin’s commitment to continuous education has provided veterans and displaced workers the training and financial support they need to be successful in our exciting industry.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

This week, I used my super sleuthing skills to select news and articles that are both driven by numbers and themes. Let’s see if my selection matches up with yours. We know our readers are opening our daily and weekly newsletters, scanning the important news of the day. The numbers tell me that. But it’s the content within those clicks that help me lock in on a clear line of thought. This week, the topic of the week: investments.

Shrinking Geometries: Back to Fundamentals to Fight EMI

Dan Beeker is technical director at NXP Semiconductors, a veteran design engineer, and an instructor who has spent years helping students and customers battle EMI through building a better understanding of electromagnetic fields and field theory. In this interview, Dan explains what happens when silicon shrinks, how feature size controls signal speed, and why this marks the perfect time to return to the fundamentals of physics and field theory.

The Industry Is Back and Better Than Ever

To say that anticipation had been building prior to this show would be an understatement. Bearing in mind the various unknowns as we emerge from the worst of the pandemic, IPC APEX EXPO 2023 stood apart as a beacon of cautious optimism. Overall, I don’t think anyone left the show disappointed. There was a real air of resurgence on the show floor related to the many new technologies, innovations, materials, and Smart manufacturing solutions being developed in the industry.

Show & Tell Magazine: Reflecting on Another Unforgettable Year

There’s always a sense of heightened expectation as we prepare for another show, and then a bit of a collective sigh when it’s over—a sigh of relief, maybe, but mostly a sigh of contentment at another job well done. Thank you for a week of unforgettable memories. The close of the show also means it’s time for our annual Real Time with… Show & Tell Magazine, the only post-show guide you’ll need. Why? Because it isn’t just a comprehensive look at what happened at the show—it’s so much more. We have exclusive interviews with IPC award winners, thoughtful observations on the show from industry leaders, pages of image galleries, special STEM event coverage, and a complete listing of the nearly 80 Real Time with … interviews conducted and posted during the show.

Real Time with... IPC APEX EXPO 2023: An Efficient Software Solution

Susan Kayesar of Siemens PCBFlow and Steven Hughes of Boardera Software, share with Nolan Johnson powerful new software solutions they’re making accessible for small and medium fabrication companies by tapping into a network of experts to optimize designs and minimize time to market.

Real Time with... IPC APEX EXPO 2023: Industry Trends With American Standard Circuits

PCB fabricator Anaya Vardya and guest editor Geoff Leeds discuss important developments at American Standard Circuits and a variety of industry trends.

Six Money-saving Material Properties When Designing PCB Stackups

Stackup decisions are critical to every PCB and electronic product, but they don’t always get the attention they deserve. With better stackup planning focusing on six key parameters, designers can select the best materials early in the design process and minimize the risk of under- and overdesigning their PCB.

Q&A With the IPC Design Competition Winner

Design engineer Sathishkumar Vijayakumar (aka Sathish Kumar V.) with Tessolve Semiconductor, India, took home top honors in this year’s IPC Design Competition, besting the other four finalists in a rigid-flex design showdown during IPC APEX EXPO. Unlike last year, no one finished the design completely, so judges graded competitors on what they did finish, as well as criteria such as design decisions they made, and whether they followed electrical and DFM rules.

Real Time with... IPC APEX EXPO 2023: We Can All Learn Something

Dylan Nguyen speaks with Charlene Gunter du Plessis, senior director, IPC Education Foundation, about careersinelectronics.com, a newly designed information-driven, industry-focused career website from the IPC Education Foundation.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

This week, we published a variety of articles, columns, and news items. But let’s have a special round of applause for Reps. Anna Eshoo (D-CA) and Blake Moore (R-UT), two members of the House of Representatives who sent the DoD a letter detailing the need for more production of PCBs and IC substrates in the United States. Republicans and Democrats have been mixing like oil and water lately, so it’s promising to see these two reach across the aisle and try to get something accomplished for the greater good.

Real Time with... IPC APEX EXPO 2023: Overseas Production

David Bishop, south regional sales director at ICAPE Group, talks with Andy Shaughnessy about overseas production, specifically out of China, as they respond to customer demand.

DFM 101: Final Finishes—HASL

One of the biggest challenges facing PCB designers is not understanding the cost drivers in the PCB manufacturing process. This article is the latest in a series that will discuss these cost drivers (from the PCB manufacturer's perspective) and the design decisions that will impact product reliability.

Real Time with... IPC APEX EXPO 2023: Updating Training Methods

EPTAC’s VP and technical director, Leo Lambert, converses with Pete Starkey about the need for updates in training methods and the use of visual tools. Training the next generation is top of mind.

I-Connect007 Editor’s Choice: Five Must-Reads for the Week

We have new projects in the U.S. Army space programs, research on gold thickness and solderability, a call for papers throughout 2023 from SMTA, an investment in Korean facilities by ASM, and an adjustment in TTM’s assignation with the U.S. DoD. All together, these five must-reads represent the hurtling trajectory that R&D seems to be following in 2023.

PCB Designers Are Really Product Designers

As I look back on 2022, I’m realizing that my company plays multiple roles in client projects beyond just designing circuits and PCBs. Sure, we’re primarily a PCB design company, but we also help with things that happen outside the PCB. This includes tasks like enclosure design, defining mechanical constraints, simulating electrical behavior, mating boards into larger assemblies, selecting cabling, and defining test requirements, all of which slowly creep into the standard scope of work for design projects.

Real Time with... IPC APEX EXPO 2023: Polar Driving Software Development for Customers

Andy Shaughnessy sits down with product specialist Erik Bateham, a new hire at Polar Instruments. Erik explains his circuitous route into circuit analysis tools. He also discusses the challenges that Polar’s customers are facing, and how user input drives Polar’s software development. If you were unable to attend IPC APEX EXPO 2023, don't worry. We're bringing you coverage of the week's events in San Diego, from ribbon cutting to teardown.

Real Time with... IPC APEX EXPO 2023: Automotive Electrification

Nolan Johnson talks with Senior Product Manager Chris Nash of Indium Corporation, who discusses Durafuse LT, a novel solder paste mixed alloy system with highly versatile characteristics that enable energy savings, high-reliability, low-temperature, step soldering, and assemblies with large temperature gradients. It also provides superior drop shock performance to conventional low-temperature solders, outclassing BiSn or BiSnAg alloys, and performing better than SAC305 with optimum process setup.

Real Time with... IPC APEX EXPO 2023: EMS Leadership Discussion

Guest editor Geoff Leeds meets with John Vaughan of Summit Interconnect to discuss his participation representing the PCB industry on the supply chain panel at the EMS Leadership Summit and the DoD roundtable, as well as trends he’s seeing in those market segments.

I-Connect007 Editor’s Choice: Five Must-Reads For the Week

It’s Feb. 3, 2023—2/3/23—and now we know the results of yesterday’s Groundhog weather forecast straight from Gobbler’s Knob in Pennsylvania. Punxsutawney Phil says six more weeks of winter. If you’re watching the ongoing ice storms blanketing much of the United States at present, that seems like a safe bet. Also a safe bet is that the most-read news this week is IPC APEX EXPO related. Additionally, this week IPC published its EMS and PCB numbers for December. All told, lots of industry news to read this week.

Real Time with... IPC APEX EXPO 2023: Wise Continues Expansion With Technica Partnership

Andy Shaughnessy sits down with Massimo Passerini, founder of Wise, and Technica's Jason Perry, to discuss Wise's latest PCB manufacturing automation. They also focus on the company's distributor partnership with Technica, which is moving into the PCB fab market. If you were unable to attend IPC APEX EXPO 2023, don't worry. We're bringing you coverage of the week's events in San Diego, from ribbon cutting to teardown.

DesignCon 2023 Opens With Strong Attendance

As George Costanza would say, “DesignCon is back, baby!” The show opened Wednesday morning, and it really felt like old times again. The aisles of the Santa Clara Convention Center were busy, and the classrooms for the technical conference were nearly full. And I spoke—or tried to speak—with quite a few engineers who spoke almost no English. That’s a good sign; in recent years, there were very few attendees from outside the U.S. because of Covid restrictions. The Pacific Rim is well represented this year.

Don't Blink: The IPC APEX EXPO Time-lapse

It’s a tradition here at I-Connect007 to set up a time-lapse for IPC APEX EXPO. There’s something satisfying, mesmerizing even, to watch the show floor build out and see the moment when the doors open and visitors fill the exhibit hall. Based on what others have said over the years, I know I’m not the only one whose favorite part is when the carpet gets rolled out and the whole character of the exhibition changes. This time lapse starts on the Saturday prior and continues through the Thursday tear-down phase.

DFM 101: Final Finishes—Electrolytic Nickel/Gold

One of the biggest challenges facing PCB designers is not understanding the cost drivers in the PCB manufacturing process. This article is the latest in a series that will discuss these cost drivers (from the PCB manufacturer’s perspective) and the design decisions that will impact product reliability.

IPC APEX EXPO Wrap-up

IPC APEX EXPO 2023 is over, and I think it was a successful show no matter how you slice it. There was barely a break in traffic on the show floor on Tuesday and Wednesday, and even on Thursday I saw people sprinting to close one more deal. Some committee meetings had nearly 200 participants; the meetings I sat in on were anything but boring.
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