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.

What are the standards for EMI and EMC for PCB design? How to meet them?

By | Date posted: | Last updated: June 30, 2022
EMI EMC Standards for PCB Design

What are EMI and EMC in a PCB?

EMC or Electromagnetic compatibility refers to the ability of the electronic system to operate within an electromagnetic environment without generating EMI or Electromagnetic Interference. EMC ensures that the system performs as intended within defined safety measures.

EMI refers to Electromagnetic Interference or disturbance where when energy is transmitted from one electronic device to another, it corrupts the signal quality and causes malfunctioning of the device.

It is therefore vital to control EMI, a task that can be done in the early stages of the PCB design. In order that your board designing is EMC friendly, a fair amount of importance needs to be given to aspects such as component selection, circuit design as well as PCB layout design. It is when your product passes the necessary EMI/EMC standards that it can be market ready.

EMC/EMI Standards for PCB Design

When it comes to EMC standards there are two broad categories of standards to meet:

  • Regulatory Standards
  • Industry Standards

Regulatory standards differ from region to region. Early EMC standards were established by the US Federal Communications Commission. The European community, later laid down its own EMC standards which are today known as the EMC Directive.

Industry standards on the other hand as their name suggests are industry-specific. That way they ensure uniformity as well as interoperability. The US Military, for example, has its own set of stringent MIL-STD EMC requirements.

Broad requirements for complying with EMC standards

In order to comply with EMC standards designers, need to look at the following aspects:

  • You need to design for EMI immunity. This largely means paying attention to the right stackup & routing strategy.
  • The design needs to ensure that the device emits minimum radiation. For his factors such as layer stack, component placement, grounding strategy, and more play a role.
  • The device also needs to suppress conducted EMI which can take several forms such as switching noise from SMPS regulators, coupled common-mode noise, and more.
  • Fast transients or power fluctuations need to be taken care of. These can appear as voltage dropouts, power spikes or more. Such requirements are particularly applicable on designs with short cables or AC inputs
  • In order to comply with EMC standards, the design also needs to withstand surges & ESD.

Here are some effective strategies that help pass the EMC standard tests:

Stackup, Power, and Grounding

If the board is designed with a low inductance ground system, it tends to minimize EMI. In case of multilayer boards placing a ground plane below the signal layers minimizes loop inductance.

It is also a good idea to route signals on an interior layer. Placing traces between two ground planes & then placing the power plane below the bottom-most ground plane is of help. Placing the power plane close to the ground plane ensures capacitive coupling.

Tight coupling needs to be maintained when routing signals from an interior layer to the surface.

Shielding

Careful use of shielding is yet another method of follow. The easiest method to follow is to use grounded shielding that forms a Faraday cage around sensitive components & traces. However this may not be possible in all designs. A grounded via fence around the edge of the board & via stitching on copper pour regions can also offer protection.

Some common types of shielding for suppressing radiated EMI include:

  • Shielding Can
  • Conductive foam
  • Wire mesh material
  • Metallic tapes
  • Conformal coatings
  • Ferrites

Differential Pairs

Use of differential protocols to route the signals where possible is preferable. Differential pairs can produce some EMI & can lead to crosstalk however this is strong only when it is very close to the pair. A differential pair will produce less intense EMI as opposed to a single-ended interconnect.

Mixed-signal Layout and Routing

It works well to separate digital, low frequency analog and RF analog sections of the board. These sections in fact need to have their own dedicated areas in the ground layer. While you need to prevent interference between different board sections you also need to ensure that signals do not have loop inductances.

Bypass/Decoupling Capacitors on the Power Bus

Use of bypass/decoupling capacitors between the power pin of an active component & a grounded via, is advised. This ensures that the residual noise is passed to the ground.

It is important that the right tools as well as the right expertise be available to design PCBs so that they adhere to EMI/EMC standards. The right PCB assembly partner can create a compliant layout as also undertake any rework.

At Technotronix, we are fully equipped to handle your PCB manufacturing requirements. With state-of-the-art equipment, we deliver the highest quality boards that you can rely on. No matter how complex your requirement, you can count on us to deliver to your bespoke needs. If you have any requirements regarding PCB manufacturing or need urgent assistance, contact us at [email protected] or call us on 714/630-9200.