Recorded conversations and interviews on electronics design and manufacturing with the editors of PCD&F/Circuits Assembly, brought to you by the Printed Circuit Engineering Association (PCEA)
Episodes
Tuesday Nov 12, 2024
Tuesday Nov 12, 2024
On today’s episode, we’re turning our focus to a pivotal innovation that has transformed design and manufacturing processes: flexible circuits.
Flexible circuits have emerged as a game-changer in the manufacturing and design of electronic assemblies. With their unique ability to bend, twist, and conform to complex shapes, they offer unparalleled advantages in applications where space is at a premium and reliability is paramount.
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.
We’ll also touch on the manufacturing complexities, material considerations, and the critical role that process control plays in ensuring reliability and performance.
Mike Konrad's guest today is Joseph Fjelstad. Joe is the founder of Verdant Electronics. Joseph Fjelstad has been active in electronics manufacturing since 1972 in various roles, including as a chemist, process engineer, and R&D manager. He holds nearly 190 US patents and numerous foreign ones.
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).
Some of Joe’s innovative devices and novel reliability improving IC packaging structural features are found in nearly every electronic device made today.
He is also an author, co-author or editor of several books on interconnection technology, including Flexible Circuit Technology 4th Edition, the most widely distributed reference book on the topic, Chip Scale Packaging for Modern Electronics, and Solderless Assembly For Electronics — The SAFE Approach.
In addition, Fjelstad has written hundreds of articles, columns and commentaries for various industry magazines and journals over the last five decades. And today, he’s the guest on my show.
00:00:00 Importance of Flexible Circuits in Modern Electronics
00:02:42 Exploring the World of Flexible Circuits
00:05:30 Introduction to Flexible Circuits: A Historical Perspective
00:08:43 Entrepreneurship Mindset: Naivety and Innovation
00:11:08 The Value of Naivety in Engineering
00:13:43 Innovations in Bubble Printing Technology
00:16:47 Understanding Flex Circuits: Applications and Challenges
00:19:58 The Lifespan and Failure of Torsion Bars
00:22:21 Evolution of Soldier Technology: From Heads-Up Displays to Wearables
00:25:24 The Origins of the Integrated Circuit
00:28:13 Advances in Microelectronics: From Printed Transistors to Modern Tech
00:31:28 Challenges and Solutions in Flexible Circuit Design
00:34:00 Collaborative Design for Efficient Manufacturing
00:36:49 Advances in Flexible HDI and the Upcoming Ultra HDI Conference
00:39:46 Evolution of Flexible Circuits: From 1903 to Present
00:42:40 Innovating Flexible Circuits
00:45:13 Evolution of Toll Road Technology
00:48:08 The Future of Flexible and Stretchable Circuits
00:51:53 Introduction to Verdant Electronics
00:54:46 The Military's Stance on Lead-Free Technology
00:56:27 Innovating Solderless Technology
00:59:18 Insights on Persistence and Success in Entrepreneurship
Wednesday Oct 30, 2024
Wednesday Oct 30, 2024
Today's podcast comes from the Surface Mount Technology Association SMTAI trade show.
As the demand for smaller, faster, and more powerful devices grows, the need for innovative solutions in circuit design has never been greater. UHDI's represent a significant leap forward, allowing for more connections in a smaller space, pushing the boundaries of what's possible in electronic assemblies.
But what exactly are ultra-high-density interconnects? Essentially, they refer to circuit boards with incredibly fine pitch interconnects, enabling higher functionality and complexity in much smaller form factors.
This breakthrough is transforming industries like consumer electronics, aerospace, automotive, and medical devices, where space, weight, and performance are critical factors.
In this episode, we’ll explore the advantages UHDI's bring to the table, from increased design flexibility and performance to better thermal management. We'll also discuss how UHDI's are set to impact the assembly process. With tighter tolerances and more intricate layouts, UHDI assemblies will require new approaches to assembly, inspection, and reliability testing.
To better explain UHDI technology, we’ve put together a panel of subject matter experts. Tara Dunn, director of training and education at SMTA, will moderate a panel discussion with other subject matter experts, including Anaya Vardya, CEO, of American Standard Circuits; Chrys Shea from Shea Engineering Services; Michael Sivigny, owner and general manager of CeTaQ Americas; and Oren Manor, Op-Center core program business director at Siemens Digital Industries Software.
UHDI is here! And if you haven’t seen it on your assembly line yet, it’s coming, so stay tuned as we unpack the future of ultra-high-density interconnects and what it means for the next generation of technology.
Tuesday Oct 29, 2024
Tuesday Oct 29, 2024
One of the most critical aspects of manufacturing high-reliability circuit assemblies is thermal profiling during the reflow process.
Whether you're designing, engineering, or troubleshooting circuit assemblies, understanding how temperatures during the reflow process influences the quality and performance of your assemblies is essential.
In this episode, we’ll break down what thermal profiling is, why it’s important, and how it affects everything from solder joint integrity to component placement.
We’ll also explore the challenges and solutions involved in getting your thermal profile just right, ensuring your circuit assemblies are built to last in a competitive and demanding industry. And we review thermal profiling best practices, common mistakes, and the various capabilities of thermal profilers.
Mike Konrad's guest is Mark Waterman. Waterman is the Electronics division manager at ECD, a manufacturer of thermal profiling equipment founded in 1964. He began his career at ECD in 2006.
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
Sunday Oct 20, 2024
Sunday Oct 20, 2024
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.
As companies seek to meet growing demand for advanced electronic products, contract manufacturers are increasingly relied upon to provide cost-effective, high-quality assembly services. Whether it's managing supply chains, ensuring compliance with industry standards, or accelerating time to market, their contributions have become indispensable. In today's episode, Mike Konrad explores how contract manufacturing works, why it's so vital, and what trends are shaping the future of this essential industry.
Adrian Leal serves as USA business development manager for Teltonika EMS and is president of the Houston SMTA Chapter. With over 30 years of experience in the manufacturing industry, he has worked extensively as both an end-user and a service provider. Throughout his career, he has held diverse roles including process engineer, manufacturing engineer, quality engineer, field engineer, and sales engineer.
In 2003, Leal became the first engineer from the oil and gas industry to earn the prestigious Process Engineer certification from the SMTA. From 2006 to 2015, he voluntarily took on the role of ESD Subject Matter Expert for SLB, where he developed an internal ESD program that remains in use today.
Leal talks about his transition from an OEM to a contract manufacturer and recommendations on how to choose the most appropriate contract manufacturer.
Monday Oct 07, 2024
Monday Oct 07, 2024
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.
Monday Sep 30, 2024
Monday Sep 30, 2024
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.
Monday Sep 30, 2024
Monday Sep 30, 2024
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.
Mike Konrad's guest is Ebad Rehman, regional product manager at MacDermid Alpha Electronics Solutions. He has a master's in technology from Illinois State University and has led multiple technical and strategic projects for MacDermid Alpha, including new product development and technology development projects, using lean and agile methodologies. He’s also planned and developed processes for the Power Electronics group and the Aftermarket Enhancement group to drive efficiencies and effectiveness.
Whether you're a seasoned engineer or someone new to the electronic assembly industry, this episode will equip you with the knowledge to make informed decisions that enhance the reliability of your electronic assemblies. Join us as we explore the critical intersection of materials science and electronics reliability.
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
Monday Sep 23, 2024
Monday Sep 23, 2024
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.
Tuesday Sep 17, 2024
Tuesday Sep 17, 2024
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.
In this episode, we'll uncover how optical microscopes have impacted electronic assembly, enhancing productivity, ensuring reliability, and driving innovation.
One of the unique benefits microscopes provide, particularly in hand soldering applications, is the ability to view and solder the assembly under high magnification through the microscope. Obviously, this is not something any AOI system can perform.
But microscopes are not limited to soldering applications. One of the most critical applications of optical microscopes in the electronic assembly industry is the inspection of circuit assemblies for quality assurance. Circuit assemblies are the heart of many products, comprising numerous, highly miniaturized components and connections that must be flawlessly integrated. Even the smallest defect, such as a microscopic crack or an improperly soldered joint, can lead to significant malfunctions or failures.
Optical microscopes enable detailed inspection of these assemblies, allowing quality control professionals to identify and rectify issues that would be invisible to the naked eye.
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.
We'll hear from two industry experts who will share insights on the latest technological advancements and how these tools are indispensable in maintaining the high standards of modern electronics. Nili Walp is marketing manager at Vision Engineering, a manufacturer of microscopes design for various industries, including the Electronics assembly industry, where she has worked for over eight years. Walp earned a bachelor's in communications from Boston University.
Richard Nagel is vice president of sales and marketing at Vision Engineering where he has worked for over 21 years. Nagel and Walp will share insights on the latest technological advancements and how these tools are indispensable in maintaining the high standards of modern electronics.
Chapters:
00:00:00 - Impact of Optical Microscopes on Electronic Assembly
00:02:18 - Latest Technological Advancements with Industry Experts.
00:04:49 - Vision Engineering's Origins and Innovations
00:07:40 - The Invention of the Boroscope
00:09:57 - The Importance of Magnification in Electronics Assembly
00:12:34 - Advancements in Microscope Technology
00:15:07 - The Game Changer in Microscopy: Eyeless Microscopes
00:17:34 - Ergonomic Advancements in Microscopy
00:20:06 - Advancements in Microscope Technology
00:22:29 - Applications of Microscope Technology
00:24:56 - Types of Microscopes in the Biological Sciences Industry
00:27:38 - Microscope Applications and Considerations
00:30:20 - The Value of Human Intuition in Inspection
00:33:06 - Common Challenges in Microscopy
00:35:52 - Illumination for Surface Texture
00:38:30 - Common mistakes when purchasing microscopes
00:40:59 - Choosing the Right Microscope for Your Needs
00:43:35 - Microscope Illumination Techniques and Considerations
00:45:57 - Practical Magnification Levels in Electronics Industry
00:48:23 - Purchasing the Right Microscope
00:50:58 - Vision Goggles in Virtual Reality and Augmented Reality
00:53:43 - Demand for Technological Advancements in Younger Generations
00:56:19 - Ergonomics and Productivity in the Workplace
00:58:47 - Learn more about reliability matters podcast
Thursday Aug 15, 2024
Thursday Aug 15, 2024
In today's episode, we're exploring automated optical inspection (AOI) and x-ray inspection technology within the electronics assembly industry.
Joining Mike Konrad are two experts who bring a wealth of knowledge and experience to the table.
Joel Scutchfield is general manager of SMT and Semicon business operations & director of sales at Koh Young, manufacturers of automated inspection and precise measurement systems with its headquarters in Seoul, South Korea, and R&D centers around the world. Scutchfield has been with Koh Young for just under 10 years.
Jesper Lykke is CEO at Viscom, a manufacturer of inspection technologies, in particular for AOI and x-ray inspection, with headquarters in Hanover, Germany and offices worldwide. Lykke has been with Viscom for 14 years.
Both Scutchfield and Lykke are widely considered subject matter experts on inspection technology.
In this episode, we'll delve into the principles and applications of AOI and x-ray inspection, discussing how these technologies are revolutionizing the electronic assembly industry. We'll explore the latest trends, challenges, best practices, and future directions, providing you with a comprehensive understanding of how these inspection methods are critical to maintaining high standards in electronics manufacturing.
Whether you're an industry professional, a tech enthusiast, or just curious about the intricacies of electronic assembly, this episode promises to offer valuable insights and expert perspectives on the inspection technologies that are driving both innovation and quality in the field. So, sit back, relax, and join us for an enlightening conversation about inspection technology.