What are the design considerations and guidelines of round circuit boards?

By | Date posted: | Last updated: November 11, 2022
Round Circuit Boards

Today, PCBs are available in a wide range of shapes, even though square and rectangular PCBs remain the most common. With the ever-developing electronics industry, the one shape that is gaining prominence is round PCBs.

As the name implies, a round circuit boards is a PCB that comes in a circular shape. It is often used in consumer electronics, wearable devices and more.

The advantage with round PCBs is that it offers increased board space. Fabrication of round PCBs however requires a lot of care since it is a complex process. In fact, the routing process of a round PCB requires a lot of time. All of this also has a repercussion in terms of the overall costs of round PCBs.

Types of Round PCB

Round PCBs, in turn, are of different types. These include:

  • Single-sided PCBs
  • Double-sided PCBs
  • Multilayer PCBs

A single sided round PCB comes with one conductive copper layer. This type of PCB is extensively used in low-density designs. Such a PCB has components on one side of the board while there is a conductor pattern on the other side. Such PCBs use either through-hole or surface mount technology.

Double-sided round PCBs have conductive layers on two sides of the board. They are extensively used when it comes to applications such as wearable devices, lighting systems & more.

A multilayered round PCB has more than two conductive layers. Even though they are the hardest to fabricate, they offer multiple advantages including:

  • They lend themselves to higher density.
  • They offer increased board space.

Round PCB Design

It is a given that round circuit boards are more complex when it comes to the design bit. Thankfully though there are few tools available that aid the design of a round PCB. There are several design rules, however, that need to be followed when it comes to round circuit boards. For example, the perimeter of such boards can only be shaped with a straight-line segment. Also, in arranging the lines of the perimeter, a circle needs to be placed on the silkscreen layer. Let us look at some more PCB layout and design rules in detail:

Round Circuit Board Design Rules

  • First & foremost, when using the CAD tool, it is important to draw the shape in the CAD tool.
  • Of course, if the round circuit board is being designed for a high-speed appliance, your choice by default will have to be a multilayered printed circuit board.
  • The power and ground planes need to be defined in separate layers. A polygon editor can go a long way to define the shape of ground or power planes.
  • Some software also offers the option of customizing the power & ground planes.
  • What also needs to be kept in mind is that round circuit boards need panelization schemes for their design.
  • To panelize a round PCB, break routing is widely used. It is imperative that a 10 mm (about 0.39 in) clearance is kept between the round circuit boards. With a larger routing tool, however, the clearance can be increased.
  • As far as the mounting technology goes, both SMT (Surface Mount Technology) as well as THT (Through Hole Technology) can be used to place components, although SMT is better suited.

To sum up

Overall with Round PCBs, designers have a lot of flexibility. The added advantage also is that there is the possibility to incorporate more features as you go along. Also, with the help of CAD tools the designer can add pad shapes in the circuit board.

While such boards are complex to design, the use of the right software can aid the designing process. Following design rules & best practices can also go a long way in making eth process seamless. It is also imperative that you deal with a professional electronics contract manufacturer who is involved in the PCB design phase itself. That way, the manufacturer can assist you with the best practices & point out any design flaws early, so that you do not have to contend with any costly issues at the fabrication stage. Needless to mention that design issues once the board is manufactured can sometimes even lead to irreparable damage to a company’s reputation.

At Technotronix, we are fully equipped to handle your PCB manufacturing requirements. With over four decades of experience in delivering high-quality, on-time, competitive price products, you can rely on us for your PCB requirements. In case you have any questions, please feel free to contact us via email at [email protected] or call us at 714/630-9200

How to fix common PCB Gerber file issues?

By | Date posted: | Last updated: December 13, 2022
PCB Gerber File

With electronic technology making its way to different fields, the use of PCBs has become ubiquitous. PCB designers & manufacturers are therefore increasingly working towards developing PCBs that are robust & more efficient. This is extremely critical especially when PCBs are being deployed in mission-critical operations where any mistakes can turn out to be extremely costly. One way to do this is to ensure that the Gerber files and the digital blueprints of the PCB are robust. Any errors in the Gerber files can prove to be fatal as they can lead to PCB failure.

Ensuring that Gerber files are therefore complete & accurate is key. Let us look at how to fix PCB gerber file problems.

Here are some of the most common ways to fix common PCB Gerber file issues:

Empty Gerber Files: It may sound incredulous, however, there have been enough & more instances where a Gerber file is an empty or a “zero-byte” file. This can happen on account of many reasons, the most common one being that the data is accidentally deleted. It is therefore imperative that each Gerber File be properly checked before it is sent onwards.

Incomplete Files: If enough attention isn’t paid to the PCB Gerber files, you could have instances where the Gerber file is incomplete. Missing information can prove to be dangerous as it may lead to a board that does not match up to the desired levels.

Improper Labeling: If the labeling of the Gerber files isn’t in line with the established protocols, it has the scope of leading to a wide variety of errors.

Too Many Aperture Lists: It is important that the Gerber File has a single aperture list with all the details. Multiple aperture lists are a source of confusion. It is also important that the format of the aperture list is the same as that of the Gerber Files.

Composite Layer Design Errors: In case composite layers are generated while generating individual layer design specifications, the images need to be combined so that one Gerber file is created for each layer.

Missing Board Outline: Sometimes when PCB Gerber files are generated, the board outline is not produced by default. It is important that the actual bounds of the board edge be described.

Missing Drill files – A drill file is required to create any through-hole footprints that might be present in the design. For software packages where a separate option is required for generating drill files, it is important that it is not missed.

Issues with other design files – It is always good to crosscheck that any revisions that have been made to your design are reflected in the Gerber files, Bill of Materials as well as the Centroid File so that there is no scope of any error.

Vectorized Pads: In some cases, rather than generating the pad as one solid object in the Gerber files, the software may output a cluster of small vectors that together form the pad. It is important therefore that the software is set at generating “ Flash Pads” as opposed to “Vector Pads”.

To sum up

While the good news is that it is easy to avoid Gerber File errors, the bad news is that any errors made can lead to far-fetched consequences; consequences that are expensive, time consuming and that can cost you your company reputation. As they say, it is better to be safe than sorry. It is important therefore that any sources of potential errors in Gerber Files are checked & fully eliminated. Some simple ways to ensure that you avoid Gerber File errors include:

  • Making use of a Gerber file viewer
  • Printing a simple board. This will allow you to see that the specifications are correct & that there are no errors or omissions.
  • Making use of high-definition CAD software
  • Importantly, making use of Quality Control practices throughout the design process.
  • Choosing your PCB partner with care. The right partner will ensure that a rigorous quality assurance process is undertaken. This will include checking the PCB Gerber file thoroughly so that there are no costly errors at a later stage & that the PCB that is manufactured is to the specifications & adhered to stringent quality parameters.

Technotronix is one of the leading providers of PCB manufacturing services to all the dominant industries. With over four decades of experience in delivering high quality, on-time, competitive products, you can rely on us for your PCB requirements. Also, you can drop an email to [email protected] or give us a call on 714/630-9200 to solve your queries or to get a quote.

What PCB certifications should your manufacturing partner have?

By | Date posted: | Last updated: June 7, 2024
pcb-certifications

When it comes to choosing your PCB manufacturing partner, it is imperative that you are certain that the partner operates within the PCB industry regulations as well as maintains quality standards. The only way you can be sure of this is if you know that the partner has the right PCB certifications as well as robust Quality Management Systems.

QMS

Let us look at the Quality Management Systems first and how they tend to improve operational efficiency:

Some of the advantages of a robust QMS include:

  • It helps improve the overall manufacturing process
  • It leads to repeatability in processes
  • It helps reduce costs
  • It improves the quality of the final product

Established by ISO 9001, the QMS helps in the following areas:

  • It ensures that all the processes follow certain specifications. Besides it also provides a centralized digitized backup for all documentation
  • It also ensures that all the industry compliances are met.
  • It aids in interdepartmental communication and therefore increases efficiency
  • It can track employee performance as also help disburse training modules.

The QMS PCB certifications definitely need to adhere to ISO 9001, however different industries can also have specific guidelines. In addition to ISO 9001, This standard applies to a company that isn’t just involved in turn-key operations in the medical industry but also if it is involved in any step of designing or manufacturing medical devices.

IPC

The Institute of Printed Circuits or IPC as it is popularly known as, also provides a number of solutions to the PCB industry & offers research on all aspects of PCB board design as well as manufacturing. Members have access to the following:

  • Industrial research
  • Process development
  • Training guides

These go a long way in ensuring that there are no manufacturing defects in the PCB. Additionally, membership also allows access to industry events, which are a gateway to information on new developments in the industry. An IPC membership, therefore, suitably assures you that the partner adheres to industry norms & therefore acts as some kind of a badge of quality assurance.

IPC-A-610

IPC also generates many standards, the de-facto standard however being the IPC-A-610. This standard is concerned with the right way of soldering as well as assembly. Here are the industries covered under Class 1 to 3 of this standard:

Class 1: General Electronics Products.

This Class refers to products where the tolerance related to defects is considerably higher & the reliability concerns aren’t so severe.

Class 2: Dedicated Service Electronics.

This is a category where the life of the products is expected to be more than those in Class 1. However these aren’t mission critical operations.

Class 3: High-Reliability Electronics.

These PCBs are meant to adhere to stringent tolerances. These are critical operations where any failure can have dire consequences. Some of the industries in which these PCBs are used include aerospace, medical & more

IPC-A-620 or IPC/WHMA-A-620

This is yet another standard that includes areas such as:

  • Crimping
  • Insulation
  • Grommets
  • Ultrasonic Welding & more

Other PCB Certifications

Some of the other important PCB certifications include:

IATR- This is extremely important in the defense industry.

UL 508A- This is used for panels in industrial usage. Some of the areas that fall under UL 508A include:

  • Switches
  • Relays
  • Circuit Breakers
  • Timers

It is however important to remember that the loads connected to this circuitry do not fall under this certification as it accounts only for the panel & the circuitry it has direct control over

To Sum Up

To ensure that your design does not meet any manufacturability issues or worse still that you do not have to face costly errors at a later date, it is very important that the PCB manufacturer is equipped with the right certifications & hence the right experience & expertise to do justice to your project. With the right certifications the manufacturer can ensure that no matter what your design challenges and goals are, they can be met effectively and that your expectations can be surpassed.

As ISO 9001:2015 & AS9100 Rev. D Certified PCB Company we manufacture high quality PCB with continual improvement in QMS to Achieve total customer satisfaction. If you have any requirements regarding PCB manufacturing or need urgent assistance, contact us at [email protected] or call us on 714/630-9200.

Why is PCB component orientation important in circuit board manufacturing?

By | Date posted: | Last updated: July 20, 2022
PCB Component Orientation

Pointing PCB components in the right direction, or what is known as the right component orientation, can go a long way in impacting both electrical performance as well as manufacturability of your PCB. This is particularly important as today’s boards need to contend with high signal speeds, issues of power integrity as well as thermal considerations. It is therefore imperative for us to look at some of the aspects of component orientation in detail:

PCB Component Orientation – what does it involve?

The right component orientation begins as early as the construction of the component footprint. Needless to mention that an incorrectly built component, even if it has the correct orientation, will not work well. It is, therefore, imperative that all the datasheets, as well as part information, are kept handy when building PCB component footprints. Utilizing the PCB design tools’ utilities and part-building wizards is also beneficial. The tools also typically connect with online library services where part information can be easily downloaded.

Small aspects such as placing markers in the footprints for component’s polarity can also go a long way in the correct part orientation.

Impact of PCB Component Orientation on Electrical Performance

High-Speed Signals

A signal path in high-speed circuitry frequently consists of multiple nets. The resistor, therefore, needs to be correctly oriented to offer optimum connection between the nets.

Similarly, high-speed routing also has memory and data buses that have several nets. The components, therefore, need to be oriented correctly to ensure that the trace routing is optimal. Similarly, with impedance-controlled nets, components need to be oriented so that connections are short and direct.

Power Supplies

To ensure optimum connection configuration the power supply components need to be oriented correctly. It is important that with high current power supply traces, routing must be short, else high resistance, inductance as well as noise can be created. To achieve this, the following measures are required:

  • There should be tight placement of power supply parts.
  • Power supply components should be placed on the same side of the board.

Often all of this will mean some unusual placement of PCB components. It is important, therefore, to check with the PCB manufacturer what is possible before board placement is undertaken.

Manufacturability

In order to ensure that PCB manufacturing is efficient, several basic rules about component orientation need to be kept in mind:

  • Two-pin components should be positioned perpendicular to the board’s direction while wave soldering. Also, it is important to make sure that tall components do not shadow small ones and thereby prevent them from being soldered.
  • Make sure that the two-pin component is not heated unequally during solder reflow as it can lead to tombstoning. In order to prevent this, metal connections between the two pins need to be equalized.
  • Components that are not oriented optimally can lead to a number of issues during rework and testing. Automated testing also requires specific clearances between test points and components.

Testing

It is extremely important that parts on the board have accessibility so that debugging & testing are made possible. If the components are not oriented optimally or are placed in a manner such that access is difficult, it causes several issues. Similarly, automatic testing requires some clearances between the test points & the components, and the edge of the board. All these aspects can be taken care of if one uses a design tool.

PCB Design CAD Tools

A CAD tool can be a valuable resource as it has a number of built in utilities that help with component orientation. You can also simplify component orientation to a large extent by changing net colors or other layout parameters. Another handy input for parts that require a fixed orientation is to restrict the ability of parts to be rotated.

Once you set the PCB design rules correctly, any part that violates these rules will lead to online warnings from your CAD system enabling you to take the right design decisions. In turn this has a huge impact on both manufacturability as well as electrical performance of the printed circuit board.

As a leading electronics contract manufacturer, Technotronix provides a one-stop solution for electronics manufacturing services with specialized support, reliable testing, and multi-functional features. In case if you have any questions, please feel free to contact us via email at [email protected] or call us at 714/630-9200.