OnTrack: The PCB Design Podcast

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Mike Konrad’s passion is educating people about cleaning their boards at assembly. If you care about Design for Reliability (DfR), you’ll learn a lot from this podcast. Mike is President & CEO of Aqueous Technologies, which manufactures, sells, and supports machines that clean circuit boards after reflow, with the goal to remove ionic residue and eliminate the chance of electrochemical migration. He is also a fellow-podcaster; hosting a show called ‘Reliability Matters’. Hear how Mike got his start in the industry and founded Aqueous Technologies and more.

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Show Highlights:

• Cleaning is optional for some and mandatory for others - it adds reliability.
• What does ‘cleaning’ mean with regard to  the way a board comes into an assembly house? Every board has a tolerance for residue, unique to its purpose and design. This means it’s virtually impossible to predict what level of contamination each board will have.
• We tell our customers that in controlled conditions, a board may have a substantial tolerance for contamination. However, you should never assume that your board starts at zero, no matter how much care goes into the fabrication or assembly process.
• The implication of dirty boards is mostly ECM (electrochemical migration failures) which manifests in one of three ways: dendritic growth, parasitic leakage, and CAF or CAFF.
• Dendritic growth is where metal crystals on a board grow between conductors, anodes and cathodes, creating shorts and causing the board to lose conductivity. Dendritic growth in a guided missile, for instance, could have disastrous implications. 
• Parasitic leakage is a rise in conductivity and a loss in resistivity, creating a current path, but not enough to cause a dead short  
• CAF (Conductive Anodic Filaments) or CAFF Conductive Anodic Filament Failure, is partially caused by micro-cracks or dry weave between the layers of a board, where the plating solution from the vias and through-holes leach into the cracks
• When considering the application, it’s essential to determine the cost of failure, e.g., a pacemaker...
• When a board catches fire, it’s pretty clear what will happen to the product housing the board.
• The Montreal Protocol was a treaty that got rid of chemicals used to clean circuit boards in 1989. Vapors from solvents and chlorine molecules were damaging the ozone layer and it was ratified by every member nation of the UN, leading to the emergence of low-residue flux (sometimes erroneously called “no-clean flux”).
• Flux is mandatory when soldering to avoid oxidization. Some assemblers turned to more environmentally-friendly cleaning products that weren’t as effective, and the rest got rid of the process.  
• Circuit boards have become denser and smaller, and miniaturization is causing more problems with the no-clean protocol.
• Don’t call it no-clean flux—low-residue flux is much more accurate. 55% of our customers who are running no-clean are cleaning. No-clean doesn’t mean “don’t clean”. Instead, don’t clean what doesn’t require it, but do clean what needs cleaning; it’s as simple as that.
• Mike relates a very telling litigation case in which an OEM couldn’t deliver the goods to its contract manufacturer (due to not fully cleaning contaminants from its boards) and tells us how litigation could have been avoided.
• IPC standards regarding cleanliness have recently been updated. 
• What should designers be demanding in the form of cleanliness? What is the cost of failure, the criticality of the product and its climatic environment? These aspects must be included in the specifications.
• There are third-party companies that will look at your design file and create algorithms to determine its propensity for failure due to residues. It all boils down to clean boards!   

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Lawrence Romine, VP of Corporate Marketing for Altium discusses what new features you can expect from Altium Designer® 20, which will be available later this year.

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Show Highlights:

• Lawrence has been with Altium for almost 15 years. At the time, the move to offshore manufacturing was prevalent and his previous experience with semi-conductors and FPGAs fit in well with Altium’s FPGA strategy. Since then, he has been involved in almost every facet of the business.
• What are the trends in the industry and why is Altium making some of the decisions we are with our product?  Mainly the extreme pressure of speed and meeting intense release dates. More than half of our customers are doing 10 new designs a year and 40% of them are doing more than 25 PCB designs each year.
• This trend brings the rise of the ‘all-purpose engineer’, however, the majority of our customers are Electrical Engineers and due to the complexities and data rates of design, engineers and PCB designers must absorb more of the technical aspects and procurement responsibilities.
• What is Altium doing to absorb these trends and enhance the user experience? Altium is clearly the number one professionally-used PCB design tool. We are now in the space where the user-imperative is paramount, meaning, we must engage with users and are in the process of aligning the entire company with that strategy. 
• We are diligent not to leave our existing customers behind. Some of our power users advised that they aren’t keen on some prior changes, so in Altium Designer 20 you’ll have, for example, a re-factored properties panel.
• The unified design model is coming back and being enhanced in Altium Designer 20, for example, dynamic, automatic compilation.
• The 3-release arc between Altium Designer 18 and Altium Designer 20 includes changing to 64-bit, changing the user interface, the new layer stack manager, and specifically, the materials library and the field solver technology. 
• The star of Altium Designer 20 is undoubtedly interactive routing–and is already being received exceedingly well. What we have now is peerless. 
• The new differential pair capability with its elegance of operation is exceptional, as well as the angle routing which can route any angle.  
• Other aspects of Altium Designer 20 set us up for future development work: the first thing you’ll notice on a very large, dense schematic, is that it will be smoother and panning and zooming are enhanced. 
• The new SPICE simulator was added by user request; all the models you can throw at it should work, but more development is underway.
• We added more advancements to multi-board design, such as ACTIVEBOM®, which now supports all the boards in a multi-board project. 
• 3D PDF support has been enhanced, we added some library migration capability to ease the transition into Concord Pro™. 
• We also added the ability to place components on the mechanical CAD side. 
• If you’re doing high-voltage design, we’ve added some new creepage rules, crossover- and return path rules.
• Where are we with bug fixing? We’ve never neglected it, but perception is a reality for the person who is experiencing an issue, so an area where you will begin to see a significant enhancement is direct engagement in our forums, on the BugCrunch itself, on the ideas forum; as a mandate from the CEO directly.
• Altium Designer 20 is addressing twice as many bugs as the previous version, which amounts to +-120 bugs being crunched, based on votes collected on Altium BugCrunch. 

Graph of Unique users impacted by bug fixes

See What's New. Altium Designer 20, A Computer Aided PCB design Software.

Jeremy Blum is the Director of Engineering at Shaper, a start-up company that built the world's first handheld CNC technology for woodworking. Jeremy talks about his keynote speech at the AltiumLive PCB Design Summit on October 21 - 23 in Frankfurt, Germany. His talk is about product development and lifecycle management from a holistic approach to engineering and design. Learn about his engineering journey from master’s student at Cornell, to GoogleX through his latest engineering adventure launching a consumer-based product at Shaper.

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Show Highlights:

• Shaper is a company in San Fransisco which makes hand-held robotic power tools. Jeremy is the Director of Engineering, overseeing the embedded software team and electrical engineering.
• Before Shaper, he was at Google X for a few years where he worked on system architecture and electrical engineering as well as design projects for Google Glass.
• He first became involved with consumer electronics design at MakerBot Industries.
• His YouTube channel, where you can still see his uploads from as early as 2006, is very popular, and he has also written a textbook: Exploring Arduino, with the second, updated, full-color edition launching very soon.
• Jeremy’s keynote for AltiumLive is titled: Holistic Product Design for Electrical Engineers​. He says his goal for this year’s keynote is to expand on the talk he gave at AltiumLive in 2018, which was about empathetic engineering.
• This year he will focus more on consumer products and the actual requirements of products working all around you, predominantly to make the process more fluid by meeting everyone’s needs.
• The reality of product design is not as abstract as it’s often made out to be. In fact, it’s very different, and Jeremy will discuss requirements that are sometimes out of your control—where compromises must be made.
• Jeremy’s inspiration for the keynote is his unique perspective from a smaller startup producing consumer products, and he’ll dive into the hands-on, full lifecycle of a product.
• It’s important to realize that despite the freely accessible tools today, there are still repercussions when IoT products aren’t reliable or useful; for example, security vulnerabilities in products used directly by consumers.
• Communication with suppliers, vendors, and manufacturers is consistently one of the most difficult parts of the job.
• Meticulous documentation is essential and helpful when it comes to working with vendors in other countries, and it becomes necessary to be able to express disappointment without the buying power of a massive organization behind you.
• The burden of knowledge is real: after PCB West, Jeremy finds himself overthinking work as he learns new ways of doing things.
• Jeremy’s approach to self-education is that it is imperative. He attends conferences, reads industry magazines and websites (taking it all with a grain of salt).
• There is no list of ‘rules of thumb’—they all have caveats. Take the time to ensure which rules apply to your situation, and understand the underlying physics.
• Jeremy feels strongly that the value of attending AltiumLive is meeting experienced people and building relationships with those who are as enthusiastic and excited about what they do.

Links and Resources:

Jeremy Blum on LinkedIn

Jeremy’s YouTube Channel

Jeremy’s new book: Exploring Arduino

JeremyBlum.com

Jeremy on the OnTrack Podcast in Feb 2018

Learn, connect, and get inspired at AltiumLive 2019: Annual PCB Design Summit. 

Jonathan Gottfried is co-founder of Major League Hacking, or MLH, the official student hackathon league. Major League Hacking’s vision is to inspire students worldwide from both traditional and non-traditional backgrounds. They’ve influenced new generations of engineers; from software, hardware, and mechanical disciplines in the events they have thrown worldwide. Learn more about Jonathan and his inspiring work at MLH.

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Show Highlights:

• Jonathan started off as a hobbyist programmer when he was a little kid, building websites and games, and playing around with different technologies. 
• As a student, he would build apps for people as a source of income, and after graduation, landed the amazing role of Developer Evangelist at Twilio Inc.
• While attending CS classes he was exposed to the massive community of passionate tech students who wanted to build things for fun and saw the considerable disconnect between what they were learning in classes and the actual day-to-day work in the industry.
• Major League Hacking is the global community for student developers. They are best known for their hackathons—weekend-long invention competitions in which developers, designers, engineers, and product people come together with their own ideas and build working prototypes in a very short time.
• Major League Hacking also offers technical workshops through its Major League Hacking localhost program, where students can learn a specific, bite-sized skill in an hour or two.
• The coaches at Major League Hacking are student leaders and role models building a diverse community on a local level.
• A new acronym, ‘STEAM’ (rather than ‘STEM’) incorporates the arts. Jon feels strongly that technology is an art and incorporates building products that resonate with people.
• Because the divide between hardware and software is blurring, Major League Hacking makes hardware available at the hacking events—exposure is the first step to becoming passionate about hardware. 
• What is the impact of exposure on non-traditional students? It can be a life-changing experience to be involved in a technical community of supportive, inclusive, passionate and creative people. It can provoke a passion which sitting in a normal class isn’t always able to achieve.  
• The impact on traditional STEM students includes gaining skills for the customer discovery process, for example; it’s a self-driven process.
• The hackathon process is: come up with an idea; get a team excited and on board, and then build the product together—encouraging more soft skills, such as team building, creative thinking, problem-solving, etc.
• In the traditional university model, there isn’t enough focus on the practical aspects of STEM because funding is mainly reserved for research.
• The barriers imposed by lack of hardware access are diminished by the prevalence of cloud hosting.
• Technology is being unleashed in this day and age, and in the coming years it’s going to be even more drastic—creators have a responsibility to ‘use their powers for good.’ 
• Major League Hacking provides resources to students for free, thanks to corporate sponsorship—get involved!   

Links and Resources:

Find out more about how your company can get involved with MLH
If you're a student, learn more about our upcoming hackathons here
Join us in October for Local Hack Day
Host a technical workshop in your club or meetup
Come work for MLH
Altium Student Stories

Follow MLH on social media:
Jon Gottfried - @jonmarkgo
Major League Hacking - @MLHacks

Learn, connect, and get inspired at AltiumLive 2019: Annual PCB Design Summit.

Happy Holden, known as the father of High-Density Interconnect and the author of The HDI Handbook, is this episode’s fascinating guest. We’ll discuss how Happy went from a small-town boy to a first-name basis with legends Bill Hewlett and David Packard, the founders of HP. Happy will be a keynote speaker at our AltiumLive Annual PCB Design Summit in Frankfurt, where he’ll discuss smart factories and how we’re going to get to the point of having digitized data. He’ll also talk about AI and his full-day talk will include HDI and the considerations you need to keep in mind. 

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Show Highlights:

• Happy feels lucky to have been at the right place at the right time throughout his career. He grew up in the mountains of Oregon in a small, highly-involved logging community.
• His math and science teacher in high school had a physics Ph.D.—not a traditional education curriculum. At university, they also had professors who were Nobel prize winners, such as Linus Pauling.
• After graduation, he was invited to interview with the integrated circuit department at Hewlett-Packard, on the recommendation of one of his professors.
• HP was more advanced than IBM when it came to integrated circuits.
  At the time, HP was making high-frequency and RF integrated circuits out of germanium and silicon placed on sapphire wafers, called “Silicon on Sapphire” or SOS.
• Intel was still a start-up at this time.
• As the first chemical engineer at HP in integrated circuit (IC) production; he was on a frontier at HP, the only chemical engineer at a company of fewer than 2,000 people—it was exciting for 21-year-old Happy Holden.
• During his 28 years there, HP climbed to 167,000 employees and from 200 million in sales per year to 54 billion!
• HP’s first 64-bit desktop machine was called a “Desktop Calculator”, because at the time a 64-bit computer was the size of a room.
• By 1972, Happy assisted Bill Hewlett in making an HP35 ‘calculator’ which was battery-powered and fit in his pocket.
• During his keynote, Happy will show pictures of the unique solution they used for the keyboard.
• At the time, they had no idea how to make a reliable gold-plated rigid-flex printed circuit board and the result was an eight-layer logic board, double-sided keyboard, and displays soldered in at an angle.
• Apart from the keynote, Happy will present a full-day class on October 21, which he calls ‘Product realization using HDI technology”; a course on the electrical performance and the advantages and drivers of using High-Density Interconnect and blowing up the myth that you have to pay more for it.
• He will be giving some insights into unlearning several aspects of multi-layers and how miniaturization should indeed save you money by demonstrating four different case studies where complex 18- and 24-layer boards were made into an 8- or 10-layers with High-Density Interconnect and less expensive.
• An interesting aspect of this full-day course is where do we go from here, what’s the next step after HDI?
• Also, don’t miss the keynote on October 23, titled “PCB Trends That Will Impact YOUR Future” and how he started working with AI 25 years ago!

Links and Resources:

HDI Handbook
Articles by Happy Holden

Learn, connect, and get inspired at AltiumLive 2019: Annual PCB Design Summit.

Today in the studio, we welcome Carl Schattke, who works for a leading electric vehicle manufacturer. Carl has almost forty years of experience in PCB Design and will teach us about the things he thinks about when designing very complex boards. He’ll discuss what he’s going to cover as a keynote at AltiumLive in Frankfurt, October 21st through 23rd, and he’ll tell us more about a talk he’s co-presenting with Max Seeley from 3M, in which they’ll discuss going from schematic to PCB layout and passing that baton like a champ. Sign up for AltiumLive now—space is limited!   

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Show Highlights:

• Carl’s earliest memory of an engineering project and the first indication of his future career was at age three when he built a helicopter out of an Erector toy set.
  His father was a mechanical/electrical engineer, and at 8 years of age, he would help with point to point continuity checks. Seeing so many designs helped him develop his own style, good symmetry, and spacing.
• The advantage of having manual experience early on over someone jumping in with electronic tools is the appreciation for using the space that’s available, but today’s boards are so complicated that without that early exposure, Carl feels he would be hard-pressed to do what he does today.
• Carl will bring artwork he did to San Diego so that young designers can get a glimpse of history.
• Carl’s keynote at AltiumLive in Frankfurt will be ‘Making and Breaking the Rules’, where he’ll discuss design rules; where we’ve come from, where we are right now and where we’re going, illustrating what’s important and what we can disregard or change. Do we change the rules?
• In what ways do design rules help or hinder today’s designers? They’re a tremendous help—the clearance rule and the Altium Designer® shadow feature is quite awesome—but in order to remain profitable, we need to understand the gaps in our rules.
• One of the most important ‘tools’ designers have is the ability to communicate with their manufacturer and engineers; asking the right questions to avoid disconnects. Getting the opportunity to connect and reflect and learn, is invaluable.
• Carl will also be doing a two-hour breakout session with Max Seeley from 3M, both in Frankfurt and San Diego; ‘Schematic to PCB Design: Passing the Baton Like a Champion’. This will be very valuable for the audience because they will talk about aspects that we don’t see in videos or read about much.
• The talk will also be beneficial to the EEs laying out their own boards because several circuits will be discussed and they still have to consider all the aspects of their process.
• What is the difference between the thinking process of pure electrical engineers, vs PCB layout pros? Depending on experience, the problems are going to be the same, it all boils down to transition line theory, resistance-capacitance, inductance, and how those things work together on a circuit board.
• Where is the baton mostly dropped? Placement expectations, simple things like what side of the board is which, non-optimal layout, leaving off the timing requirements, leaving differential pairs unlabelled. Many little details can have a huge impact.
• These talks will be very practical in terms of authentic design review—things that are not generally dropped on a schematic and much more.
• Sign up now, space is limited!

Links and Resources:

AltiumLive October, San Diego
AltiumLive, October, Frankfurt
Picture of Rick Hartley on a light table
Carl and Julie’s talk at AltiumLive 2018

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Today we speak with Bob Martin, a Senior Staff Engineer with Microchip. Bob is also known as ‘the wizard of make’, and today he’ll discuss his AltiumLive Keynote on October 11th in San Diego where he’ll teach on how to go from prototype to production with Arduino Board, transitioning it into a production-ready board that you can manufacture.

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Show Highlights:

• Bob graduated from the University of Saskatchewan, Canada in 1987 and spent his entire career in embedded systems, ending up at Microchip Technology with the unusual job title ‘Wizard of Make’ which originated at Atmel.
• The title ‘Wizard of Make’ comes from a discussion to progress his job description at Atmel. Being enamored with makers, and a maker himself - he has attended every maker fair in the Bay Area since its inception. The word ‘wizard’ came from describing some of his talents.
• Bob’s talk at AltiumLive will encompass the many facets of Arduino which enable rapid prototyping and doesn’t require starting designs over during transition to production. He will detail mostly the hardware aspects and how to make the transition to production easier.
• Because of the complexity of systems and the need for rapid prototyping today, the ease of using products like Arduino are becoming more prevalent. You need to be able to talk to your electro-mechanical designer and be more involved in systems-down thinking.
• Quick paths to production through Arduino: there are things that you need and others that you don’t and the keynote will explain what to keep and what to discard to ensure lower production costs.
• Ben will also discuss concepts of testing: where to put test points and why they’re more cost-effective, as well as lowering BOM costs.
  Pete Wilson, from Microchip, will do another talk about dropping pre-certified RF models on designs.
• The ecosystem of products like Adafruit, CircuitMaker, SparkFun, Pololu, MikroElektronika are all very easy to use, relatively inexpensive and almost plug and play, once again enabling rapid prototyping.
• The name ‘Arduino’ is the name of a bar in a town in Italy where Massimo Banzi taught and they used to gather there to discuss the product. Arduino’s software system made things easy, leveling the embedded field.
• Who would this talk be of interest to? Anyone who is interested will be enlightened about what, hardware-wise, makes an Arduino platform, and receive an extension of their knowledge about ACE (Arduino Component Elements).
• What is a professional maker? The pro-maker could be an electrical or mechanical engineer or some other technologist who has recognized a problem or has an idea, using Arduino or a similar system to implement a solution, but in the back of their mind, there’s always the matter of the implications of going into production.
• Eric Bogatin’s talk ‘A Downside of Open Source Designs’ fits in very well with Bob’s regarding the software component and what to look out for when using open-source designs.

Links and Resources:

History of Arduino
Jeremy Blum - Handheld shaper tool video

Learn, connect, and get inspired at AltiumLive 2019: Annual PCB Design Summit.

Welcome back, today we speak with Dr. Eric Bogatin who is the Dean of Signal Integrity at Teledyne Lecroy. Eric has agreed, once again, to be a keynote speaker at AltiumLive, San Diego - October 9th to 11th and today he shares more with us about his keynote and the courses he teaches at Colorado University, Boulder, some books he’s writing, and the makers he serves. There’s no grass growing under this man’s feet.

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Show Highlights:

• LinksEric has spent most of his career in the signal integrity field on multiple sides of the fence, including R&D, product and tool development, which was his springboard into education, keeping him busy for 30 years.
• After selling his company to Teledyne le Croy, as they’re now known, he is still focusing on best design practices, and how to eliminate problems before they happen.
• Currently, Eric is more focused on best measurement practices, or how to use scopes and other instruments to analyze a product and find the weak links and root cause of issues.
• At AltiumLive this year, Eric’s talk, ‘Breaking Bad,’ encapsulates best design principles and the downside of open-source designs as well as in-depth, specific design features on boards.
• Approximately a million Arduino Uno R3 boards have been manufactured in the last ten years, but they have many ground bounce issues and terrible return path control - Eric uses them as an example of how NOT to design a two-layer board.
  Using open-source designs may lead to bad habits. At AltiumLive he will discuss how to use the Arduino design and show how to measure ground bounce and implement the right design guidelines - refer to Seven Design Guidelines link below.
• The message of the keynote is: don’t apply what you see in a popular open-source design, believing that it’s the right way of designing.
• Right after the keynote, Eric will be doing another talk on ‘Mastering the TDR in 45 Minutes’.
• The TDR is the most valuable instrument to characterize, as a first pass, electrical properties of circuit boards, but it has several little-known applications in the lab environment, which will all be discussed.
• Besides his work at Lecroy Eric is also involved in writing textbooks and another book on the design and characterization of transmission lines through Horizon House/Artech.

Links and Resources:

Article: Seven design guidelines, Signal Integrity Journal

Learn, connect, and get inspired at AltiumLive 2019: Annual PCB Design Summit.

Mike Buetow, the Editor in Chief and Vice President of Printed Circuit Design & Fab magazine as well as Circuit Assembly’s magazine, joins us to talk about PCB West. The publishers UP Media put on PCB West every year in Santa Clara, this year’s will be September 9 to 12. We talk about what you can expect from the show, how it got started and some colorful history from their background. Altium is also a sponsor of the show this year, and we’ll be there with a booth and Ben Jordan will be giving a class; ‘The Absolute Beginner’s Guide to RF Design.’

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Show Highlights:

• After two semesters of applied math, Mike switched courses to journalism and ended up working for a trade magazine in the SMT industry. He also worked for IPC for six years where he became embedded in this industry.
• PCB West predates UP Media by almost a decade, the original conference and exhibition launched in 1991 and is now in its 28th year.
• What sets PCB West apart as a conference after 28 years, is the in-depth format itself; a deep dive into tutorials on printed circuit design and manufacturing.
• 70% of the sessions this year, will be at least two and a half hours long, there are also 20 half-day workshops and 5 full-day workshops.
• There will be 14 talks on EMI/EMC and noise control, 20 involve some element of DFM or board fabrication, and more than 20 will cover high-speed design. The sessions are longer, attacking subjects from all angles.
• PCB West has seen considerable growth over recent years due in part, to holding it in September rather than the first quarter of the year, and has been sold out for the past eight years.
• Highlights at PCB West this year include: Eric Bogatin with two presentations, Lee Ritchey with a not-to-be-missed, full-day high-speed tutorial, Daniel Smith from Raytheon will discuss an AI development to address CAD/CAM design bottlenecks. Altium’s Ben Jordan, who is a real designer’s designer, will also be there talking on RF and microwave design.
• Susy Webb and Paul Cooke will be covering a variety of basics to include schematics, layout, and fabrication.
• Rick Hartley, the most popular speaker in the history of PCB West is back with seven presentations, including new talks on design for IoT devices.
• Joe Fama will explain his model on how Tier 3 EMS companies can compete with Tier 1 companies on BOM costs.
• Greg Papandrew is representing his new company ‘Better Board Buying’ and will highlight how to improve procurement processes.
• ‘Free Tuesday’ offers 13 free sessions including Eric Bogatin on SI and PI, and a very participative session on ‘21 (and Counting) Most Common Design Errors, Caught by Fabrication, and How to Prevent Them’ by Dave Hoover, TTM Technologies, Ray Fugitt, Downstream Technologies and Mike Tucker, Kinwong Corporation.
• Writing Your Résumé and Marketing Yourself Within Your Company by Gary Ferrari will be very interesting as it’s an often-neglected area.
• PCB West has changed over the years; today we see many more degreed engineers - a fun component (think ‘The Porch Dogs’) has been added, timing has changed, but one constant remains - the educational component.
• This year there will be a one-day exhibition on September 10, with 110 exhibits offering a lot of hands-on, equipment suppliers, demos and around 20 board shops with product samples, also some assembly people, and much more. For pre-registered attendees the exhibition is free, admittance on the day is $25, so do be sure to register on time.

Links and Resources:

PCB West Guide
Tuesday, September 10 Free Sessions
Exhibitors List
UP Media Magazines
PCB Chat Podcast 

Learn, connect, and get inspired at AltiumLive 2019: Annual PCB Design Summit.

Welcome back to the OnTrack Podcast. Today we speak with Mark Forbes, Director of Product Marketing at Altium, about the history of IC development and how that directly impacted you and will continue to impact you and your design practices. Capturing some of the history is important so that we know why we do things that we may not have known happened 30 years ago - you’re really going to enjoy this deep dive into what’s happened over the last 30 years and how it impacts your career every day.

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Show Highlights:

• Mark has spent his entire career in electronics, equally divided between hardware and software.
• PCB design has been dramatically affected over time by the trajectory of ICs.
  The 8080 microprocessor exploded the idea that we don’t have to design discretely, but could program a computer to do all our functions.
• The main effect of increased integration on PCB design is that so many functions have been shrunk into a single chip and how to get those out to other parts of the board, is a major problem.
• The higher speeds create more heat in these smaller spaces and heat dissipation/cooling is also a major problem.
• Geometry is a huge factor in why we are able to integrate more stuff on the same chip, for example in 1971, the geometry was 10 microns (µ); on the current Snapdragon, it’s 7 nanometres (nm). If you had a thousand-page book that represents 10 microns; one twentieth of one page is 7 nm.
• Now we’re running into some physical issues such as speed - the original 4004 ran at 740 kHz, and the Snapdragon runs at 2.9GHz. If you put that into perspective, if the 4004 was a car, and you’re going 60 miles ph, the Snapdragon is going 65 miles per second.
• Speed has become important because of EMI/RMI. Back in the day the 8080 ran at 1mHz, and an antenna was a few feet long, none of the traces on the board acted as resonant antennas so, there was no radiated signal - only radio designers were concerned with frequencies and gHz whereas now, these concepts apply to the vast majority of PCBs.
• We are getting near the physical limits that can’t be broken. For example, sometimes as you try to locate a memory on a pc board that’s too far from the processor, the electrons can’t get there in one clock cycle, which is revealed by data errors. We are now fighting the flight time of an electron.
• To increase speed there are only two things you can do: 1] more cores 2] change the geometry to accommodate physical limits which are the speed of light and the size of an atom.
• Every time we leap forward with the ICs, it directly impacts board design, how do we keep up with that? Ongoing engineering education; online trade magazines; manufacturer seminars.
• Curiosity is exceedingly important.
• Where are we headed? In 20 years we probably won’t be using electronics… there will be some fundamental breakthrough.
• Telling the stories of history will inspire more development, again, stay curious!

Links and Resources:

Charles Pfeil Presentation: Effective Methods for Advanced Routing
Customer success story of increased yield rate of corn

Learn, connect, and get inspired at AltiumLive 2019: Annual PCB Design Summit.

Today we have an extra-special guest named Joe Grand of Grand Idea Studio. Joe started hacking software and hardware at the ripe old age of seven! He ended up becoming a part of hacker history and you’re going to love hearing about it. He’s also co-founder of The Badgelife movement, and co-host of a Discovery TV channel called ‘Prototype This.’ We’re delighted to announce that he’s agreed to be a keynote speaker at AltiumLive, October 9 to 11 in San Diego. Registrations are now open and we encourage you to sign up now because space is limited.

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Show Highlights:

• Joe got involved with computers in 1982 and has always been fascinated by computers and electronics. When he discovered the hacker community, he fell in love and was able to make a career of it.
• They started filming ‘Prototype This’ in 2006/2007 with the producers of ‘Myth Busters’ with the aim of following the real-life engineering of building projects, showing engineering to the masses in fun ways to share the process and even explain technical concepts to grandparents.
• Joe started using Altium Designer® in the very early days and still does so to design his badges.
• The Badgelife phenomenon started at Def Con through Jeff Moss, known as Dark Tangent. It also led to the idea to present training at conferences, ushering in Joe’s training program ‘Hardware Hacking’ which he still teaches to this day.
  Many people are starting to make and sell badges, it’s almost a gateway to a professional engineering career.
• Joe demonstrates his flex substrate badge for Def Con China. This is where he learned to use the Altium teardrop function.
• The Def Con USA badge included blind vias and via in pads which Joe had never worked with and once again Altium Designer came to the rescue. They went from six prototypes to 28 650 pieces in one week.
• Joe’s pseudonym is Kingpin - why do hackers have pseudonyms? Most of them grew up in the hacker world, where connecting to bulletin boards required a nickname, it was about having an anonymous identity in the hacker world back then.
• The hacker world now has many different branches and is more focused on not taking everything at face value, asking questions and being curious.
• Joe relates his experience with the group called ‘L0pht’ where they were called before the US Senate to testify on the state of computer security in government.
  Joe will bring a world view of a hacker in engineering to AltiumLive in his keynote address: ‘When Hacking and Engineering Collide’ to include design tips, projects, and crazy contraptions built for television to mention a few.

Links and Resources:

Grand Idea Studio
Twitter (@joegrand)
A History of Badgelife, Def Con’s Unlikely Obsession with Artistic Circuit Boards
For Hackers, Anonymity Was Once Critical. That’s Changing

Def Con China Tree
L0pht Heavy Industries
L0pht Senate Testimony Video
https://en.wikipedia.org/wiki/L0pht
https://www.washingtonpost.com/sf/business/2015/06/22/net-of-insecurity-part-3/
https://duo.com/decipher/an-oral-history-of-the-l0pht
AltiumLive San Diego Keynote Speakers

Learn, connect, and get inspired at AltiumLive 2019: Annual PCB Design Summit.

Today we talk to Rick Hartley about EMI, noise control and why it can be so difficult to get under control in your PCB designs. Listen in, because this is really a sneak peek into the full-day class Rick will be presenting at AltiumLive.

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Show Highlights:

• What in your childhood gave you some clues that you’d end up being an Engineer? It started with trying to repair an old alarm clock at age 5, by the time I was 12 I was dabbling in radios and repairing home appliances by age 14, which made it obvious that I would end up going in this direction.
• Rick has agreed to teach a full-day class at both of this year’s AltiumLive Summits in San Diego and Frankfurt; the title of his class on October 9 in San Diego is Keys to Control Noise, Interference and EMI in Printed Circuit Boards.
• What inspires this topic? During the mid-eighties, many issues became apparent, listening to Lee Ritchey motivated action and they formed a design council with Rick sharing the information, which continued growing to where we are today.
• In September 2019, Rick will also teach at PCB West as well as Eric Bogatin, Lee Ritchey, Susy Webb, Gary Ferrari, Mark Finstad on Flex Design, Dan Beeker - and the list goes on.
• Altium will also have a booth at PCB West where Ben Jordan will speak on RF Design and do demonstrations.
• AltiumLive is not just for Altium users, Rick believes the thoughts generated at these summits are extremely valuable.
• Why is the AltiumLive class so important for designers today? Everything is fast because the rise times of IC outputs have become so fast.
• Faster rise times equates to higher frequencies, it doesn’t matter what your clock frequency is, what matters is what devices you use.
• According to Dan Beeker, most of his customers design expecting to fail EMI the first time. People need these classes to ensure solid design from the outset and passing EMI the first time.
• Dr. Bruce Archambeault recently quoted that there really is no such thing as voltage.
• Topics that will be covered at AltiumLive: The relationship between energy and noise; what to look for when you’re selecting ICs; the impact of frequency; length versus distributed circuits; the basics of grounding and grounding methods; the keys to controlling common mode current - the leading cause of EMI; routing and termination styles of transmission lines to prevent reflections and signal integrity problems; basic component placement and the impact it can have on EMI; IO connector placement and IO connector pin-out; routing to control EMI; power delivery; capacitor placement relative to via inductance; decoupling boards with routed power; how to create proper power distribution on boards based on their stackup.
• Rick will be presenting the same talk in Frankfurt at AltiumLive October 21.
• Registrations for AltiumLive will be opening soon, don’t miss it.

Links and Resources:

Previous Podcasts with Rick 
Last year’s AltiumLive Keynote
Cartoon ‘the knack’
PCB West 2019 
AltiumLive 2019, San Diego

Learn, connect, and get inspired at AltiumLive 2019: Annual PCB Design Summit. 

Gerry Partida is back to talk to us about wrap plating and via filling and what the benefits, requirements and drawbacks of this technology are, and what you need to know about designing these and how this technology drives cost.

Show Highlights: 

• Gerry is the Director of Engineering at Summit Interconnect with 35 years’ experience in the PCB industry, of which he spent 2 decades in boardshops. 
• Were there indicators in your youth that you would end up in an engineering profession? Growing up NASA was in the middle of the Apolo program and being mesmerized by that was the beginning of it all. 
• Definition of wrap plating: Wrap plating wraps copper onto the surface whenever we have a blind via or epoxy-filled hole, ensuring safe expansion and contraction during assembly.
• Benefits of wrap plating: saves real estate and protects via and with high-speed digital, it speeds up response times.
• IPC specs for wrap plating: IPC 6012 for rigid boards, 6013 for rigid-flex, and 6018 for RF. IPC4761, titled Design Guide for Protection of Printed Board Via Structures.
• The minimum wrap thickness at the knee of the hole changed recently - but the thicker the wrap, the harder it is to etch. Studies have shown that as long as you have some wrap, it’s reliable.
• By plating, epoxy-filling and plating over, we eliminate the chance of the solder going down a via next to a BGA pad.
• What are ‘butt joints’? 
• Talk to your manufacturer about the optimum drill size and the requirements for epoxy-filling to prevent dimples or protrusions.
• If you have a blind via job, you must specify that they are to be filled and plated over. 
• Gerry shows a hand tool that measures copper thickness around all the panels. It is used to verify, after planarizing, the lowest location and verify and cross-section to ensure that you are safe on thickness specs.
• A board shop will build in verification processes which take time -  when you add epoxy-fill to a job, there are eight major manufacturing steps added to the job, which takes 24 hours in the quickest board shop. Basic board manufacture has approximately 26 to 28 steps.
• Make sure your fabricator does all the required steps for filling in-house.
• Minimizing wrap cycles creates greater consistency in your RF performance on an outer layer.
• Peel strength: when we epoxy-fill a hole it creates a smooth surface at the hole which weakens the peel strength.
• Thermal vias - conductive pastes do not conduct as much heat as copper - forget thermal paste, ask your manufacturer to plate 2mm of copper in the hole, just make the hole a bit bigger.

Links and Resources:

IPC Standards

Altium YouTube Channel

Previous Podcast on IPC4761

Summit Interconnect Website 

In this episode we talk with Robert Feranec, a familiar name to many of our listeners. Apart from being a popular YouTuber, he’s also the founder and CEO of FEDEVEL Academy where he teaches PCB Design to people around the world. Robert shares what it takes to be a popular YouTuber, the work it takes to produce all the great content he creates and as a special bonus we’ll discuss Robert’s Keynote that he will deliver at AltiumLive PCB Summit this October in San Diego. 

Show Highlights:

• Robert considers himself lucky to have started working on complex boards almost immediately after university. This early start provided much experience and he soon began freelancing.
• As a freelancer, he did whole-board design i.e. specifications, schematics, layout, as well as testing and firmware. 
• He found he often couldn’t remember everything when using Altium Designer® and started doing YouTube videos, at first for himself, but soon garnered a following and today he has 24 000 followers.
• As he became more popular, he received many email questions daily, which was very time consuming and he decided to create a forum where he offered a course, and the rest is history. Robert teaches Altium Designer but also CAD-independent content.
• What goes into creating a video tutorial? Lots of preparation, a half-hour video takes almost two days to create. One hour of video training takes a week to create.
• AltiumLive Topic: How Other Companies Implement Their Hardware Design Process. Many people ask about how other companies implement hardware design, create and use libraries, collaboration (design flow) and working faster.
• Why do so many people only use a small percentage of their tool’s capacity? Most don’t need all the features. Many are nice to have but not always a necessity. Also, people learn to use the tool in a specific way and adding new features could interfere with an established workflow.
• Robert’s talk at AltiumLive will provide insight into libraries, creating new components, component lifecycle, creating new symbols as quickly as possible, ensuring correct footprints, and more. 
• What are the challenges around collaboration? Communication between different types of engineers and how to manage several engineers working on the same project.
• What about versioning and backup? Most companies will do both in the same way.
• Document releases are very complex, there are too many emails back and forth. Robert will talk about ensuring correct documentation and release procedures.
• What attracts people to your training? The different levels of the courses, the variety, and junior designers love them to upskill and get better jobs.

Links and Resources:

AltiumLive Summit 2019

Ben Jordan Podcast

Lawrence Romine Podcast

Altium Academic Page

Robert’s YouTube

FEDEVAL Academy 

Robert’s LinkedIn 

Today we’re going to talk about the importance of learning, as Eric Bogatin emphasized at last year’s AltiumLive. Please join my conversation with Ben Jordan where we explore a variety of ways that you can continue to learn and drive your career forward.

Watch the video, click here.

Show Highlights:

• A current hot topic on the forum is the value of CID or Certified Interconnect Designer Certification. This certification fills in many knowledge gaps not necessarily learned in college, such as the materials sciences and these classes are taught by gurus who started out as materials scientists.
• CID and CID+ are offered by IPC and are very useful by including how to present the results of your design to all the other stakeholders like testers, fabricators, and assembly. 
• The IPC was floating the idea of recertification and it was not well received mainly due to the cost. 
• Lack of practical experience is a barrier to job entry.
• Multi-disciplinary and systems-based thinking are terms we often see as criteria for finding jobs, not only the core technical skills.
• We would love to hear from our audience on whether a formal certification on a tool would help your career? 
• IEEE has a recognition path called a Certified Professional Engineer which requires continual learning to maintain. 
• The common thread from most industry experts is that continued and ongoing learning is crucial.
• The motivation for learning is the excitement of new technologies and most PCB Designers are very curious people by nature. 
• PCB Design is never monotonous, every board is a new board. 
• Robert Feranec will be a keynote speaker at the next AltiumLive; his curiosity drove him to research optimizing the hardware design flow in your company and he will be presenting his conclusions. 
• AltiumLive is open to anybody, not just the Altium Designer user - pre-registration is now open.
• Keep your eye on our YouTube channels and our next Podcast.

Links and Resources:

Kelly Dack Podcast: What is PCB Design? 
Circuit Assembly/UP Media article that raised the whole question on CID. 
AltiumLive Summit 2019
Altium YouTube channel

Amit Bahl, the Director of Sales and Marketing at Sierra Circuits, is here today to discuss a more holistic view of not only board fabrication, but also assembly as Sierra Circuits does both. He’s going to teach you ways to think more about your total cost of ownership. We also do some fun myth busting around PCB fabrication and assembly.

To watch the video, click here.

Show Highlights:

• Amit says his story is pretty simple: he’s here to service PCB Designers, whatever they want or need, Sierra Circuits makes it happen and have been doing so for 30 years in Sunnyvale, California. Amit spent his high school years setting up drill machines and packaging circuit boards and got his training very early on. His father started the business in 1986. 
• Their business is quick-turn and they do PCB fabrication, assembly, component procurement, all really quickly from a few buildings on Evelyn Avenue.
• Tips on looking at fab and assembly more holistically: The number one mistake is a failure to send boards in, in an array; customers tend to forget to send the array panelized drawings but Sierra takes care of that for their customers. 
• What data do you really need upfront? Two types of data, first for the quote and also for manufacturing.
• For quotes: Gerber or ODB data or IPC 2581 data. Then there’s everything else for fab that has to be perfect: material, surface finish, any special requirements, PCB stackup; all detailed out in a fab drawing including impedance and dielectric control.
• It’s imperative to communicate with the fabricator and visit your board shop. It helps designers understand what happens on the floor, to see where variations can come in on different machinery and to design keeping in mind that each process is in a different department.
• Some myths surrounding fab and assembly. Websites are not always updated regularly, you cannot design based merely according to what’s on the website. Pick up the phone! 
• PCB materials only hold up for a maximum of three to four laminations because of thermal stress. 
• Don’t trust the data sheets, even for electrical properties - every material behaves differently. Isola 370HR is very reliable and consistent.
• Price and value are not equal - look at the total cost of ownership. Do you hire supply chain first and put pricing pressure on vendors, or are you hiring a quality department first and putting quality pressures on the vendors? Focus on quality and attention to detail is essential.
• Trust begins with relationships and with trust, specific aspects can be left to the fab house.
• Sierra will be at AltiumLive 2019, October 9 - 11 in San Diego, where face to face relationships can begin.
• Sierra is launching a Google Maps Street View for their facility, where designers can ‘walk through’ the shop virtually. This should be ready within the next three weeks.
• Trends: HDI, laser drilling, flex & rigid flex.

Links and Resources:

Sierra Circuits Website

Amit LinkedIn

What is Design? Podcast with Kelly Dack

AltiumLive, San Diego, October 2019

Sierra Circuit’s HDI Design Guide

Today we have a treat for you; we’re going to talk to two bright, young leaders at Advanced Assembly, Chao Vang, who’s the Engineering Manager there, and also Sebastian Weber who’s their Process Engineer. Both have come up through Advanced Assembly, learned in the trenches and they’re going to share great tips with you on how to make sure that your assembly is done right the first time and this will save you a lot of headaches.

Show Highlights:

• Chao’s degree and background are in Computer Engineering and Electronics Technology. She started off at Advanced Assembly ten years ago as the Coding Engineer; did sales for two years, and has been in her current role for two years now.
• Sebastian has a degree and background in Electronics Engineering and quick-turn assembly. He started as a Receiving & Shipping Supervisor and due to his technical knowledge, gradually got into more technical positions and eventually Process Engineer which he’s been doing for three-and-a-half years.
• Located in Aurora, Colorado, Advanced Assembly is the original quick-turn PCB assembly service shop; the pioneer in these services 15 years ago. Built from the ground up, they are specifically geared towards prototypes and small quantity quick-turns.
• Over the years they’ve assembled over 40 000 unique designs. With a staff complement of 105, their focus is that they are real people, with real experiences ensuring their customers get exactly what and when they need it.
• What happens after you receive the data package and files? Critical files required for DFA (design for assembly) check are: BOM, XYRS (pick and place files), and all the layers of Gerbers which must include copper, paste and silkscreen. For customers who don’t have all the files, we can create them.
• Most jobs (in fact, 95%, go on hold initially due to missing files.
• What is the first step for process engineering? Review files for special assembly notes, identify designs that aren’t necessarily the best for manufacturing and communicate on issues long before the actual build.
• What issues most routinely come up on the process engineering side? Via in pad especially on BGAs, glass top micro-BGAs, overage on very small parts.
• Common issues in front-end engineering: in the BOM, parts called out are not the same as in the description, for example, capacitors and resistors as well as polarity issues.
• How many parts on an average board? Between 250 to 500 - the DFA check takes almost two hours depending on complexity and some jobs have thousands of parts.
• What can your customers do to speed things up? Talk to the assembly house and ask what they need. A schematic and list of special requirements can help tremendously.
• Tips from engineering: Keep suggestions and feedback from the assembly house and do these implementations upon the next revision to avoid rework and related costs.
• How would customer’s implementing your suggestions impact you as an assembler? Mostly shorten lead time by preventing jobs from going on hold.  
• Better planning means better results - partner up with your assembler and save money.
• All front-end engineering is done before a purchase order is even produced, meaning, the customer doesn’t pay for the DFA check.
• Parts sourced during the quoting phase through proprietary software and Octopart® shortens the sourcing time from an hour, to an average of 5 to 7 minutes!
• It’s been confirmed that Advanced Assembly will be at AltiumLive, October 9 - 11, 2019

Links and Resources:

• Bil Herd from Commodore Podcast - Commodore
• AltiumLive, San Diego, October 2019

Today we meet with Rob Cooke, Director of Engineering, and Jose Cordero, Lead CAM Engineer from Calumet Electronics Corporation in Michigan. We talk about something that’s often overlooked, which is making sure your data package references the most current revision of IPC Standards. Listen in as we discuss slash-sheets, ENIG, and Via Plugging.

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Show Highlights:

• Jose jokes that nobody goes to college to end up in PCB fabrication. His background is in Art and Sound Design specifically. After completing his studies at Michigan Technical University he found Calumet Electronics, and the rest is history.
• Rob has been in the industry for almost 18 years, mostly doing design work in electronics for aircraft and military systems. He was appointed as the Director of Engineering at Calumet three months ago.
• From humble beginnings, Calumet Electronics has expanded to the point where today they produce between 600 and 800 panels a day, and over 3 million parts per year.
• The facility is unique in that it’s housed in a railway roundhouse - a very unique setting for a circuit board manufacturing factory.
• What are some of the things that slow down production due to insufficient data packages? A lot of confusion about IPC Material callouts.
• In 2017 there was a major update to IPC 4101 that changed the nominations of what materials are grouped under which category and materials are still being called out with the old specs.
• Designers need to pay more attention to their fabrication notes, and not reuse the same material callouts from previous designs. New spec updates are frequently missed, particularly in medical, aerospace and military parts where the design was produced five to ten years ago.
• Why are designers not aware of the update to IPC 4101? The pace of change can accelerate the development of the spec, and when IPC does make changes, it may not always be communicated well enough to end users.
• Via types: IPC 4761 describes seven primary types; some of the main ones are used interchangeably, even when that’s not the intent.
• Two main via types are type 5 and type 7 obviously selecting the correct type will influence both turnaround time and total board cost.
• Some folks try to specify some level of filled or capped via not using a spec but coming up with their own design notes.
• Things that throw us off: Materials instead of a class of materials are specified - there are many epoxies available. When a specific material is called for it could lead to extended wait times.
• We encourage defining plugged or capped vias by spec - the notes are ambiguous, vague, and cause the most problems.
• ENIG changes: There was a change in the spec this year. More gold is not better - the 4552 standard now has a maximum limit for gold, to prevent corrosion - whereas before there was only a minimum level.
• What is hyper corrosion and why it’s a problem: the gold is deposited on the nickel through a replacement process where each atom of gold replaces an atom of nickel - the more gold we add, the more nickel is removed, creating phosphorous molecules which is not a solderable surface.
• Designers need to verify on their drawings that specs haven’t changed.
• Ultimately the data pack is a way of communication between the designer and fabricator and it should be crystal clear. It’s also a critical point of reference for inspections.

Links and Resources:

Calumet Electronics Corporation
IPC Standards: IPC 4101 and 476, 4552

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Today we talk with Greg Papandrew who’s just started a new company called Better Board Buying. With more than 27 year’s experience in PCB sales, he knows all the inside tricks to help you get the most out of your vendor partnerships and to save money and time.

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Show Highlights:

• Greg started in the industry as an inside sales and customer service guy. Believing he could provide a better service to his customers, he started The Bare Board Group in 2002, did that until 2013, and then ventured into consulting and helping customers acquire the best boards. His recent experience of the disconnect of buyers within the industry regarding their training led him to start his company to educate his customers in buying and to understand what they’re buying.
• What does Better Board Buying offer? Help buyers and engineers to buy boards better and what to look for. Improve the service that buyers are getting and help them realize that they can get better products and service - raise their expectations, most importantly bring back the personal touch. Better Board Buying offers a personal discussion about vendors, getting more buying power, taking care of all the hidden costs such as freight. Also, negotiating consignment stock and managing expectations.
• What has been lost since your start in the industry and today? I’ve been told my methods are ‘antiquated’ but they are, in fact, time tested. It does come down to relationships. The client’s confidence in the vendor to help them with any new job or problems, no matter the time of day, has been lost. Focus on the bottom line has negated the question, ‘what service are you getting for your dollar’? 
• We have lost sight of the fact that the board is not just an item on a BOM that is bought on price only.
• Engineering and purchasing should collaborate more. Collaboration, inclusion, and buy-in from everyone is key.
• How should an engineer or designer think about a prototype and what does it mean to you to begin with the end in mind? First, determine the number of pieces, consider the purpose of the board, ask how it will be manufactured – a collaboration between design and manufacture is essential here – again relationships… Do you have corporate specs for PCBs to cut down on questions at the beginning?
• Why have we lost the cohesion and personal touch? The interest in manufacturing may not be what it used to. Perhaps procurement experience is not necessarily in PCB manufacturing and we lack that expertise.
• What are you personally doing to turn this thing around? LinkedIn articles, speaking at different conferences, word of mouth.
• What can people in procurement do to educate themselves? There’s plenty on the OnTrack Podcast, Circuits Assembly, PCB007, going to trade shows and talking to people there. It’s a skill you can acquire.
• What things in a board design can contribute to sticker shock once a board does go to production?  There are many, but a few of importance: clarity on the finish, don’t over-design, cop away board thickness, how much routing or score is there (to save time), solder mask thickness, controlled impedance. Also, talk with your vendor, many board houses also have design engineers.  

Links and Resources:

Greg LinkedIn
Greg’s article: Where have all the young PCB bloods gone?

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In this episode we’re filming at Michigan Tech with guest Dr. Chris Middlebrook who teaches a class on Printed Circuit Fabrication. Watch or listen in on our first OnTrack Field Trip as we sit down in Dr. Middlebrook’s lab, where they make circuit boards right on campus. We talk about students, the education program at Michigan Tech and all the hands-on work they do to prepare Electrical Engineers for the real world.

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Show Highlights:

• Dr. Middlebrook has been a professor at MTU since 2007. At this engineering-focused university, they take a hands-on approach to help create engineers that are well-versed in practical design and implementation.
• What is MTU doing regarding the shortage of talent in the industry? The resurgence in manufacturing across all sectors calls for students being fully equipped and they strive to equip their students with the necessary skill set to drive the next generation of technology.
• Several lab spaces enable students to get hands-on with chemical and wet processes as well as prototyping and research, board etching and development. They work in small groups across campus.
• Calumet is very close to campus, they have been instrumental in the success at MTU, involving their engineers and scientists to get things up and running, they supplied much of the raw materials.
• Students eagerly sign up to tour the Calumet facility once they have experienced all the processes in class. Student feedback is very positive.
• Why is there a disconnect from the hands-on side of this work pervasive in most universities? Costs of materials and chemical sets is a primary factor. Not many students are interested in tinkering with things but that mindset is changing.
• What else can the industry do to support this initiative? Lab sponsorship, one concise, larger facility as a showpiece would make it more practical and create more opportunity for visibility to parents and students.
• More interaction and mentoring is something students respond to very well.
• Guest lectures pique student interest and broaden their experience across the spectrum.
• Topics covered in lectures: From electroplating within PCBs, to solder masks to assembly and multi-layer press to the future of this industry by Happy Holden.
• Positive elements of the Millennial culture: They’re very knowledgeable, already know where they are and where they want to be, they do a lot of things before getting to University.

Links and Resources:

Contact Dr. Middlebrook

Altium Academic Website

MTU

Calumet Electronics

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