How To Avoid Common Problems With Gerber File During PCB Manufacturing Process

By | Date posted: | Last updated: April 8, 2022
pcb manufacturing

Printed Circuit boards vary in size and composition depending on their application. From basic PCBs used in standard applications to highly complex PCB configurations used in advanced applications, PCB designers are under constant pressure to design highly innovative yet efficient and functional PCB’s that can get the job done faster, better and easier. Leading edge applications like satellite guidance systems or even advanced automation systems require even more innovative PCB solutions to keep up with technological evolution in other controls. But irrespective of whether the pcb layout is simple or complex, the design phase typically ends with a series of Gerber files that serve as input for PCB manufacturer during the manufacturing and fabrication process. Gerber files can be defined as PCB blueprints in digital format used in the layer by layer manufacturing and fabrication of Printed Circuit Boards. A big part of the quality process in the manufacturing of Printed Circuit Board’s involves ensuring the Gerber files are exact and complete. Incorrect or incomplete Gerber files can result in the manufacture of faulty or non-performing PCB’s.  There are multiple Gerber files that get generated for every Printed circuit board and ensuring that each one of them is not only complete but accurate as well is critical in ensuring the end product is able to perform as per specifications.

There are many errors that can occur during the creation of Gerber files, some of the more common ones include:

Missing or incomplete Gerber files

Not all Gerber files created for the same PCB are equal in size and specifications. For instance an Excellon Gerber drill file contains specifications regarding the location and size of the holes, plated and unplated to be drilled in each PCB layer.  Each Excellon Gerber file needs to be complete along with the ASCII code and the tool number to be use for hole drilling for that particular layer. A single missing detail can change the entire configuration of the PCB by changing the size, shape or location of the hole on the board, which is why it is important to ensure that there are no incomplete or missing Gerber files.

Missing Aperture List

The basic purpose of an aperture list is to provide details regarding the kind and location of the tool to be used at each stage of the PCB manufacturing and fabrication process. When multiple aperture lists are generated for each layer or when the aperture list is generated in a format different from the Gerber files, the possibility for errors increase. Having a single detailed aperture list containing specifications for all the layers and in the same format as the Gerber files reduces the chances of errors and malfunctioning.

Zero byte Gerber PCB files

Sometimes design errors can lead to the creation of zero byte Gerber files that contain no information that can be used for PCB manufacturing and fabrication. It is important to check the validity of the Gerber file before sending it across to PCB manufacturers.

Incomplete or misleading Gerber file labelling

Each Gerber file needs to follow a standard naming convention that makes it easy for the manufacturer to understand its intended use. An incomplete or non-standard file labeling can create interpretation issues for the manufacturer leading to production errors and delays.

Insufficient inner clearance

Inner clearance can be defined as the minimum clearance required between the drill hole and the interconnected, adjacent inner layer copper on the printed circuit board. If the inner clearance is not sufficient, it can cause short circuit in the inner copper layer during the drilling process.

Errors in Making Composite layers

Some design software’s use compositing of layers while creating design specifications for individual layers. This can include layers with both positive and negative images and while compositing can help speed up the process it can also cause errors especially if the images are not combined properly to create a single Gerber file for each layer.

Gerber file errors can prove to be a costly and time consuming, not to mention completely avoidable. Ensure your PCB Making, manufacturing and fabrication process remains error free depends a lot on ensuring Gerber files are accurate and complete, which is possible by practicing the following steps

  • When it comes to ensuring error free operations, there is nothing like establishing best practices at every step of the design and manufacturing process. This includes checking the Gerber files for completeness, correctness and length as well as validity.
  • Use a Gerber file viewer to check the Gerber files for accuracy and validity. A Gerber file viewer allows designers to validate the size of the final actual PCB and even print a sample board to check for size.
  • Use advanced CAD software during the design process that are less prone to errors, some high definition CAD software are even able to provide designers with a basic design analysis before creating the actual Gerber files to be sent to PCB manufacturers and fabricators.

Adhering to these practices along with rigorous quality checks at every stage of the design process can ensure that the PCB’s manufactured by you are both high performing as well as long lasting.

Technotronix is one of the leading provider of PCB manufacturing services to all the dominant industries. Having a strong manufacturing unit with a strong tool room and a team of experts, we are the one that provides cost effective solutions with keeping quality at the nucleus in each stage of PCB manufacturing. To get proper consultation or share your requirements to get a perfect PCB with cost effective strategy or to get a quote, drop an email to [email protected] or give a call 714/630-9200!

PCB Fabrication Is Molding An Upward Curve Of Innovations In Building Protection System

By | Date posted: | Last updated: September 7, 2024
PCB Fabrication

Be it a residential building, hospital, shopping mall, hotel, school, educational institution or any kind of a building, the security of the building is a prime facet to get a complete building solution. This also includes protecting the building, its assent and the human life from the airborne toxic industrial chemical, radiological and biological attacks or any accidental release apart from fire, water, earthquake and other security concerns. For these high value security solutions, the upgraded technology for the building safety system is now a top priority, especially in the commercial building sector and residential constructions. To introduce a completely new concept and a unique solution, it is necessary to focus on the dynamic electronic design and manufacturing solution in consultation with the custom PCB experts.

The printed circuit boards used in the making of the building security devices have many PCB manufacturing techniques with which one can create an altogether a unique modification in the new and existing electronic equipment. The modification and discovery in the building protection system have an increased use of state-of-the-art PCB fabrication Innovation like Through-Hole-Technique, Surface Mount Technique, Cable Harness, Wire Harness and Box Build PCB assembly. To know about the ups and downs of the building security systems, it is also important to stay updated with the new innovation of the current times in the global market. Some of them are listed as under which has the highest requirement of varied pcb layout and fabrication services.

PCB Fabrication Innovations in Building Protection System:

Robust Fire detection System:

The flexible PCB is the foremost element in manufacturing the automatic fire detection technology and multi sensor devices for fire detection. This has also made it possible to get a hybrid instrument for fire detection that can also apply the modern signal processing techniques like fuzzy logic and neural network. This has made possible to bring new modifications in the fire risk assessment and fire fighting equipment for the building protection.

Electric Locking Mechanics:

The electronic devices having multiple functionalities like keyless electronic system, large scale entry solutions, retrofitting interior enclosure system, electromechanical lock and many more devices are used to provide security needs of electric locking mechanics.

Lightning Protection System:

The Lightning Protection System (LPS) provides safety of building from the destruction by the power of lightning that is directed towards the ground. For this, the rigid/flex PCB and cable harness PCB assembly are widely used in the electrical elements used in this lightning protection system with simple rods, triggering system and with taut wire. Among all, the lightning surge arrestor is in the mainstream that is used to protect the building from the havoc of lightning that can wreak on the delicate electronic instruments installed inside the building. These arrestor are installed on the electrical service panel that has a proper coat onto it that is capable enough to resist the direct lightning strike. This type of building protection system is majorly used in the metal covered buildings.

Fire Alarm System:

With rigid/flex printed circuit board and PCB prototypes, the fire alarm specialists are now able to bring new creative inputs into the device functionalities. Depending on the size of the building, the type of fire alarm system is decided as it has complex installations in the building. These consist of the hardwired system, conventional system, radio linked system and analogue addressable fire alarms.

Electric Smoke Detector:

A PCB used in smoke detection alarms need complex engineering and rigorous testing process to get a long estimated life of the batteries used in smoke detection devices installed in the building. Be it a hardwired AC operated or battery operated smoke detector, ionization and photoelectric technology has brought further improvements in the product performance and durability.

Induction loop and hearing enhancement system:
The wired or wireless induction loop system and hearing enhancement system with a high tech loop driver and audio source helps to catch the clear sound without interference.

Another new innovation is marked in the electric gauge door opener, cathodic building and structure protection, smoke alarms, burglar alarm, door monitoring and locking and fire door control devices. Above all the buzz word in building security market is the Eco-Friendly safety and security solutions to protect the building with the safety of the environment and human life as well.

TechnoTronix proffers a custom PCB prototype and PCB manufacturing solution with the help of well defined PCB fabrication process and fully equipped tool room. With a passionate team of technical experts, we provide complete turnkey solutions with quick turnaround and timely delivery of order to our customers. Having good PCB assignments of building protection devices and equipment, our research team has made us one of the renowned players in providing electronic and layout solution to the building security and safety requirements.

Get a quick quote for PCB Fabrication Services!

Printed Circuit Board Becoming A Vital Arena for Bringing Creativity In Audio Devices

By | Date posted: | Last updated: April 8, 2022
PCB-circuits

The audio device industry is set to grow in parallel with the technology triggering across the globe. Also the entertainment and hospitality industry has created an increased demand of audio devices at large. With the enhancement coming up in consumer applications every other day, the recent trend of implementing wireless technology in audio devices has captivated the attention in the market with its growing popularities all over the electronics industry. The recent audio discoveries have marked cosmic developments in the new product launch, business partnership and acquisition globally. With this, the audio device makers are now in race to present a multi featured compact device with giving an appealing dimension experience to the end users in order to survive in the electronic market. The base to audio innovations is the printed circuit board. This article provides interesting updates on the recent innovations in audio devices and the use of printed circuit boards at the very base to new discoveries in audio device market worldwide. TechnoTronix has expertise in serving Wireless PCB Assembly to audio device market.

Innovations in Audio PCB:

The present world of electronics has made the humans to use electronic devices right from the carry cot to the tomb. The golden age of audio technology driving innovations in the last few years have made an avalanche of audio tools for the music enthusiasts and audiophiles. The continuing technological transformation has led the analysts to speed up the research to bring out a fine fusion of product, application, technology and geography to meet the on-going audio device requirements of the customers.

With this, the product developments are seen in the speaker system, sound bar, microphones and headset with engineering the wireless technology in every novelty. The current trends in audio device are an overture to the consumer application, automotive, defense, commercial application and security operations. The Bluetooth, airplay, WiFi and many more technologies have made it possible to innovate one stop solution in a single audio instrument with portable, wireless and connected audio devices coming on strong tech adoption.

Audio PCB application in household gadgets:

With increasing research in the audio device market, the researchers have marked the household application of audio gadgets to be positioned at the class level of sophistication. The Bluetooth enabled headphones and the wearable health trackers that helps improve the wellness with entertainment and productivity experience is a fine instance of attaining the sophisticated flavor in the household electronic device. The TV, smartphone, Blu-ray player, laptops, DVD player and other electronic gadgets are enjoying the leadership in growth map of innovation.

Wireless Audio Device Market:

Few standout in audio innovations that are under active development, prototype, concepts to be released or expected to ship soon in the market in the near future include laser lights equipped with the headphones that set pulse to the rhythm and your favorite music by giving you feel of the wearable expressive audio tool, the virtual Reality (VR) technology is clubbed with audio devices to give a compelling audio visual experience and many other game changing innovations.

One of the most interesting enhancement is noted in a WiFi guitar cable bringing notion in the wireless audio technology. Also a note of creative music studios with wireless protocols, making it possible to connect the audio instrument, sound cards and devices. The Artiphon Instrument 1 is at the rim of the basket in the world of innovations. This innovation makes it possible to play numerous instruments with different ways on a single device controlling through an IOS device. This will bring a new trend in hybrid instruments. A gestural music system that allows to control music with gloves is pushing the boundaries of audio technology.

The foundation of all these innovations is the proven printed circuit boards. The PCB used in audio gadgets have proven design, flexibility, tech savvy board design and inbuilt technologies of miniaturization and advanced Etching technology with high precision surface mount techniques. The PCB with laser via, multilayer printed circuit boards, BVH printed circuit board, high density PCB, FPH printed circuit board and double sided PCB are in trend to suffice the requirements of audio device makers. The above circuit boards provide the optimum solution for the amplifiers, sound to vision, splitters, mixing desk, microphones and recording desk. The enhancement is also seen in the conductive paste with connectivity technology in the inner layer of the board, fine pitch CSP assembly, through hole technique with perpetual hole processing method, via-on-pad configurations and smaller device form factors. These developments in PCB fabrication have made it possible to bring the ideas into reality which can be exemplified by the launch of the bionic hearing module that is majorly used in the medical industry in current times. This super advanced technology is brought into a mini device that is developed by a large margin with flexible printed circuit boards.

The material used in PCB for audio devices must absorb moisture to get better productivity in the gadget. For this, the PCB manufacturers are staying active in the application of the new concepts to give variety with perfect product to the audio device manufacturers. Thus the researchers are focusing towards the creative innovations in PCB manufacturing for analog devices, amplifier PCB board and other PCB for audio devices.

At Technotronix, we are fully equipped to handle your PCB manufacturing requirements. With over 4 decades of experience in PCB manufacturing service as well as assembling PCBs with differing levels of complexities, we follow industry best practices to ensure we deliver cutting-edge products. Our team of experts and state-of-the-art equipment ensures that all our PCBs meet the industry standards of quality and testing. It is our vast portfolio of satisfied clients that stand as the biggest testimony to our success. In case if you have any questions, please feel free to contact us via email at [email protected]

PCB Fabrication Fuelling A New Revolution In The World Of Computers

By | Date posted: | Last updated: May 28, 2021
PCB Technology

Steadily staking claim in the future of the computer industry, a high tide of companies race to integrate hybrid technology trend in the computers. Mobilizing the power of next generation networks, an array of innovations is traced in computer hardware mechanics. The OEM’s, startups, EMS and other manufacturing units are cropping up with fresh ideas to deliver an effective solution to the end users. This has also made the printed circuit board market to give a good chase with new electronic and design solutions. A flurry of developments is marked in the computer PCB’s ruling the electronic world. This article summarizes the recent facts of technology shifts in the electronic world with making the use of printed circuit board in the mainstream. It also provides a short brief on a buzzword sensitive in the market that has led to exciting developments is the Eco friendly concept.

Tracing inflate signs in the life of computers is a result of the technology slump for the past few years. With this, various dominant “clone” are coming up with an exciting hybrid electronic solution with taking computers to the next level of advancement. As a result, numerous software programs and off the shelf computer components were the only outcome. Taking the world in its stride with universal application, computers have shown and is showing a remarkable innovations to make the planet a magical one.

Innovation in Computer PCB

The recent innovations are heading towards construction of a computer device that is connected wirelessly to the internet with the help of sensors making Internet of Things the name of the game. Other technology shifts are focused on nanotechnology, artificial intelligence, self assembling materials and other flexible electronics to bring out a super computerization in the electronic market. Staying parallel to the trends in the market, Digital Transformation and Data Science are making a breakthrough in the information gap by giving customers a digital real world experience. Other sensitive verticals include cyber security, 3D printing and Augmented reality.

Going to the roots of electronic discoveries, the initial strive to lead the innovations are the printed circuit boards. The rigid flex printed circuit boards is highly in use to manufacture the compact computers having a custom functional foundation to make a feature rich PC. With the fresh ideas flushing in the market, many types of PCB’s are now a part of PC production. To get a simple, low density design, single sided PCB is used in the PCB fabrication process. Allowing the routing of traces in the circuit board, double sided PCB is fashioned with proven designs to be a quick fix in computerized mechanics. The multi layer PCB fetches dense and complex outlay to suffice the hybrid computer requirements in this present world of innovation.

The main board of the computer, Mother Board is the general PCB found in the expandable systems and microcomputers providing connection to other peripherals. It is attached to the interface cards and daughter board. The technical world strives to come up with an advanced handy pcb layout for these complex foundation that can make the computers more and more durable and user friendly in nature. The structure is connected to an adaptor card, processor chips, memory modules and other electronic components. The piggyback board, so called daughter board is an extension of the main card. Having a strong internal connection the structure is linked with the plugs, connectors, sockets and pins. These have their application in the enhanced graphic adapter, network interface controller, Bluetooth, server management, modem, robots and many more. The developments are also marked in flex connectors installed on computers to put the ideas into action.

Recently, the innovations in green gadgets and Eco friendly technology is at the nucleus across the globe. It has now become a prime choice to opt for computers having a fine Eco blend between electronics and the environment. At the same time challenges are also seen in creating a unique fusion of powerful graphic processor and CPU to bring out new discoveries in the world of computers. This has made the researchers to adopt hybrid technology to take a next step in launching a high tech PC. The printed circuit boards are now designed to get a lightweight, compact multi featured computer that can also suffice the need of a user friendly piece of work.

Furthermore, the enhanced computer world has also made it possible to rock and roll the innovations in the robotics and other electronic industry. These developments have showcased an increase in the use of computers, but at the same time have also focused to keep the Environment at the rim of the basket to protect the mankind.

Driving the computer industry to a path of Eco friendliness, the Chicken Electronics is the upcoming action in research and developments. This concept of “Best From Waste” will be a sincere point of concern to make an Eco friendly PCB from the feathers that consists of fiber and are strong enough to be used in the circuit board manufacturing. This shows that the environmental protection is the delicate affair becoming a prime matter of concern for the PCB manufacturers. Thus, computers have been the base product to give the wings to new innovations in the electronic world.

At Technotronix, we are fully equipped to handle your PCB manufacturing requirements. With over 4 decades of experience in PCB manufacturing as well as assembling PCBs with differing levels of complexities, we follow industry best practices to ensure we deliver cutting-edge products. Our team of experts and state-of-the-art equipment ensures that all our PCBs meet the industry standards of quality and testing. It is our vast portfolio of satisfied clients that stand as the biggest testimony to our success. In case if you have any questions, please feel free to contact us via email at [email protected]