PCB Chat

On today’s episode, we’re turning our focus to a pivotal innovation that has transformed design and manufacturing processes: flexible circuits.

From wearable technology and medical devices to aerospace systems and consumer electronics, the use of flexible circuits has expanded rapidly, bringing with it both opportunities and challenges.

In this episode, we’ll explore the evolution of flexible circuit technology, discussing its key benefits, such as lightweight construction, enhanced durability, and improved design freedom. 

He is an internationally recognized expert, inventor and lecturer in the field of electronics interconnection technology and a veteran of several startup companies, including: Beta Phase, ELF Technologies, MetaRAM, Silicon Pipe, and Tessera (now the public company, Xperi).

Today's podcast comes from the Surface Mount Technology Association SMTAI trade show.

This breakthrough is transforming industries like consumer electronics, aerospace, automotive, and medical devices, where space, weight, and performance are critical factors.

One of the most critical aspects of manufacturing high-reliability circuit assemblies is thermal profiling during the reflow process. 

Chapters:

00:00:00 Understanding Thermal Profiling in Circuit Assemblies 

00:05:19 Evolution of a Manufacturing Business 

00:08:00 Understanding Thermal Profiling in Electronics Soldering

00:10:36 Strategies for Circuit Assembly Insulation 

00:13:10 Challenges in Sourcing Obsolete Electronic Components

00:15:48 Challenges in Heat Dissipation for 5G and 6G Electronics

00:18:54 Choosing the Right Thermocouple: K Type vs. Others

00:21:35 Challenges with High-Temperature Materials

00:24:04 Determining Thermal Couples for Optimal Measurement

00:26:39 Innovations in Profiling Equipment Technology

00:29:24 Innovations in Display Screens and Risk Mitigation

00:31:55 Cost-Benefit Analysis of Data Loggers 

00:34:31 Importance of Calibration Intervals in Industry 

00:37:02 The Role of Data Logging in Thermal Profiling

00:39:30 Optimizing Reflow Oven Settings with Predictive Software

00:42:18 Easy Button vs. Detailed Work: Software Development Insights

00:45:20 Common Mistakes in Using Thermal Profilers 

00:47:37 Optimizing Thermocouple Measurements in Electronics 

00:50:08 Understanding Thermal Barriers and Heat Management

00:52:22 Understanding Thermal Dissipation Challenges

00:54:59 The Importance of Third-Party Auditors in Manufacturing

00:57:32 Insights on Thermal Profiling and Bespoke Solutions

00:59:54 Podcast Contact and Closing Remarks

If you're part of the electronics landscape, you've likely encountered the role contract manufacturers play — and it's a critical one. These specialized partners bridge the gap between design innovation and full-scale production, bringing efficiency, expertise, and flexibility to the table.

Sales of software for printed circuit board and multichip module design surged 8.2% to $399 million in the second quarter ended in July, continuing a long recovery, the ESD Alliance announced today.

Our guest Wally Rhines offers his typical informed assessment of the latest market numbers, noting the particular strength in core areas such as analysis and library data management tools. And he discusses how the rapid rise of EDA startups today compares to a similar upswing in the 1980s. 

Jim Rathburn may not be a household name in the printed circuit industry, but maybe he should be. A self-styled serial technologist and innovator, Rathburn holds more than 80 patents covering the gamut of high-density printed circuits, materials and semiconductors.

As founder and president of Precision Circuit Technologies, Rathburn helps commercialize the Minneapolis area company’s high-performance, high-density printed circuits, electrical interconnects, and advanced materials for the next generation of semiconductors, electronics, and systems.

He discusses PCT's technologies, in particular with liquid crystal polymer, and its use of both additive and conventional processes to build lines and spaces down to 6 microns. He also details PCT's zero-discharge processing, and licensing approach.

As the demand for more durable and dependable electronics continues to rise across industries, the choice of soldering materials, such as solder paste, plays a pivotal role in determining the reliability of these devices. We'll discuss how selecting the right solder paste can influence performance and longevity, and we'll hear from an industry expert about the latest advancements and best practices in soldering material technology. 

Chapters:

00:00:00 Importance of Soldering Materials in Electronics Reliability

00:02:06 Evolution in Soldering: From Lead to Lead-Free

00:03:53 Trends in Automotive Industry Adaptations

00:05:59 Understanding High Reliability in Different Industries

00:08:04 Enhancing Material Reliability for Safety-Critical Applications

00:10:12 Classifications of Reliability in Electronics 

00:12:29 Selecting Solder Paste for Wearable Devices in Harsh Conditions

00:14:29 Ensuring Reliability in Electronics 

00:16:27 Understanding Electrochemical Reliability in Circuit Design

00:18:27 Understanding No-Clean Solder Paste Reliability 

00:20:29 Choosing the Right Powder for SMT Applications

00:22:37 Understanding Type Numbers and Their Industry Impact

00:24:44 Addressing Environmental Concerns in Soldering Materials 

00:26:52 Achieving Sustainability Goals with Recycled Tin 

00:29:00 The Benefits of Zero Discharge Practices

00:30:56 Thermomechanical and Electrochemical Reliability Challenges

00:32:59 Emerging Trends in the Electronics Industry

00:34:54 Challenges in Thermomechanical and Electrochemical Reliability 

00:36:53 Standardization and Industry Collaboration

00:38:56 Best Practices for Consumer Buying Habits in Electronics

00:41:05 Future Trends in Electronics Reliability 

00:43:16 Embracing Change in Electronics Assembly Industry

00:45:12 Evolving Soldering Materials and Environmental Standards

00:47:01 How to Engage with the Reliability Matters Podcast

JITX is a San Jose-based developer of PCB design automation tools. The company's novel platform takes design concepts and convert them into schematics, circuit design, and component placement, among other features.

Duncan Haldane, CEO and cofounder, talks with Mike Buetow about the JITX platform, which proposes to rethink and simplify the way electronics are designed by using common language instead of machine code to realized complex ideas as a product design, overcoming legacy technology, and working on the desktop instead of the cloud. 

And (teaser alert), listen for an announcement about the premiere PCB Design Community event taking place on October 9 at PCB West at the Santa Clara (CA) Convention Center.

Two episodes ago, in RM 149, we talked all about automated optical inspection. Today we're exploring the impact of less automated inspection Technology, that being optical microscopes.

From commercial, class 1 electronics to high-reliability class 3 electronics, the intricate electronic devices we rely on daily are assembled with astonishing precision. This precision wouldn't be possible without the aid of advanced optical microscopes. These remarkable instruments allow technicians and engineers to inspect, analyze, and ensure the quality of electronic components down to the minutest detail.

By providing high-resolution images and magnification, these microscopes help in detecting defects, ensuring correct alignment and polarity of components, and verifying the integrity of solder joints. This meticulous inspection process is crucial for maintaining the reliability and performance of electronic devices, ultimately ensuring customer satisfaction and, in many cases, safety.

In today's episode, we're exploring automated optical inspection (AOI) and x-ray inspection technology within the electronics assembly industry.