PCB Chat

RM 180: Low Temp Soldering for a High-Reliability World

Note: This is the fourth of four episodes on the subject of soldering materials.

 

Today, we're diving into a topic that's reshaping how we think about thermal management, energy efficiency, and long-term performance in electronics manufacturing—low temperature soldering. Joining Mike Konrad is Dr. HongWen Zhang, principal metallurgist and R&D manager of the Alloy Group at Indium Corporation.

 

Dr. Zhang is not only a seasoned materials scientist with a Ph.D. in materials science and engineering, a master’s in materials science and engineering and in mechanical engineering and a bachelor’s in metallurgical physical chemistry he’s also coinventor of Durafuse, a family of solder alloys that are redefining what's possible at low reflow temperatures—which, reportedly, does not compromise reliability.

 

In this episode, we’ll explore how low temperature solders are helping manufacturers lower energy consumption, protect heat-sensitive components, and still meet the rigorous mechanical and environmental demands of today’s electronics—from wearables to wafer-level packaging. We’ll also talk about the challenges of brittleness, drop shock resistance, activation and encapsulation of no clean activators, and how cutting-edge materials research is solving problems that used to be considered trade-offs.

 

Whether you’re a reliability engineer, a process expert, or just solder-curious, this episode is packed with insights you won’t want to miss.

 

PCB Chat 147: Matthias Wagner of FluxAI

Today’s guest is Matthias Wagner, chief executive and cofounder of Flux. Flux is maker of a Agentic AI-based PCB design platform and programmable simulator that runs in a browser environment. Regular listeners may know we have spoken with Matthias a few times in the past, most recently in February 2024.

Since we last spoke, Flux has built out its platform with a variety of tools for design planning, parts searching, netlist generation, design review, firmware coding and testing and debugging, to name a few.

 

We discuss

• AI-powered PCB design challenges
• Language prompting capabilities 
• Democratization of product design, and
• Technical specifications and platform limits.

 

 

 

RM 179: Indium's Ross Berntson

This is the third of four episodes on the subject of soldering materials.

Today, we’re continuing our deep dive into the world of soldering materials, from advanced alloys and flux chemistries to global manufacturing strategy and materials innovation, with one of the industry’s most respected leaders. Joining Mike Konrad is Ross Berntson, president and CEO of Indium Corp.

Berntson has been with Indium for nearly 30 years, starting as a product specialist and rising through the ranks with leadership roles in product management, technical support, and international operations. He even spent time leading Indium’s Asia Holdings while based in Singapore, strengthening the company’s presence across Southeast Asia. In his current role as CEO, Berntson sets the strategic direction for a global materials powerhouse, one that’s known not only for its high-performance soldering products but for its commitment to innovation, collaboration, and engineering support through the company’s “One Engineer to Another” philosophy.

Berntson holds degrees in chemistry, teaching and an MBA from Cornell University, where he earned several prestigious academic awards. He’s also deeply engaged in both the electronics industry and his community, serving on multiple boards and leading with a strong emphasis on culture, opportunity, and respect, the core of what Indium calls “The Indium Way.”

In this episode, we’ll discuss how soldering materials are evolving to meet the demands of modern electronics, from miniaturization and harsh environments to UHDI and advanced packaging. We’ll also talk about Indium’s unique positioning in the industry, the challenges of global supply chains, and what the future of soldering looks like from the vantage point of a company that’s helped shape it.

PCB Chat 146: The Latest EDA Market Results

Wally Rhines joins Mike Buetow each quarter to share details from the latest ESD Alliance report on sales of PCB design software, computer-aided engineering tools, semiconductor tools, related IP and services, and employment.

This chat, we discuss the long PCB/MCM design tool rally, a massive jump in employment. broader strength across the ECAD industry, and the effects US policies toward China are having on the market.

 

RM 176: The Chemistry of Reliability: Choosing the Right Solder and Flux

In this episode, Mike Konrad is joined by Chris Ward, founder and managing director of Solderking Assembly Materials, a UK-based manufacturer of solders and chemical consumables for electronic, electrical, and engineered assemblies.

Ward brings decades of experience in soldering materials and chemical formulations—and he’s built a company committed to performance, consistency, and innovation.

Earlier this year, Ward and his company were honored with the prestigious King’s Award for Enterprise in International Trade, recognizing their exceptional export growth. That recognition earned him an invitation to Windsor Castle, where he had the distinct honor of meeting King Charles III.

Today, we’ll explore the evolving world of soldering materials—from the realities behind “no-clean” flux, to reliability challenges in harsh environments, to innovations in solder chemistry that support today’s miniaturized and mission-critical electronics.

Whether you're on the production floor, in the design lab, or managing quality and reliability, this is a conversation that brings valuable insight into the materials behind the mission.

PCB Chat 147 with Margaret Upshur of Mobius Materials

Margaret Upshur is CEO of Mobius Materials, a global online marketplace for excess electronic components. Before founding Mobius, she was senior director of operations at Particle, which supplies application infrastructure for deploying software and models on computing or IoT devices. And while in college she cofounded a company that made a hand-held device to detect the alcohol content of liquids.

Noting some $15 billion or more is wasted each year in unused or obsoleted components, Upshur founded Mobius to provide a platform for trading excess inventory much in the way Wall Street brokers trade stocks. 

We discuss her model for a sustainable, resilient supply chain; why the buyers and sellers on the Mobius platform can trade anonymously; as well as the PCB Community Meetup featuring a panel on the Ever-Changing Procurement Environment Mobius is sponsoring at PCB West on Oct. 1.

RM 177: Humidity: Small Cause, Huge Reliability Risk with Viktoria Rawinski

Chapters:

00:00 Introduction & Episode Overview

02:12 Meet Victoria Rawinsky: Expertise & Industry Impact

05:09 Social Media Challenge & Making Science Accessible

09:09 Humidity in Electronics: The Science & Risks

15:12 Types of Humidity & Effects on Materials

20:04 Manufacturing Shortcuts & Hidden Failures

25:30 Real-World Reliability Failures & Case Studies

31:02 Miniaturization, Board Layout & ECM

35:52 Best Practices: Cleanliness, Coatings & Moisture Mitigation

41:32 Material Choices, Standards & the Invisible Risks

45:51 The Smell Test: Practical Tips & Final Thoughts

47:16 Upcoming Events & Community Involvement

48:18 Outro & How to Stay Connected

 

PCB Chat 146 - Stephen Chavez on PCB Design Trends and Needs

Stephen Chavez is principal technical product marketing manager with Siemens, but he’s best known for his three decades as a printed circuit designer and instructor. He’s a regular contributor to various industry publications and host of the Printed Circuit Podcast. He also coauthored and teaches the PCEA Training Certified Printed Circuit Designer curriculum, and is chairman of PCEA.

He talks about some of the issues designers are running into, his upcoming presentations at PCB West, and the design-related programs at the college level, where he has been teaching of late.

 

RM 175 - SMT War Stories with Phil Zarrow and Jim Hall

Mike Konrad is joined by two of the most respected names in the electronics manufacturing industry, Phil Zarrow and Jim Hall. Together, they bring decades of hands-on experience and unparalleled insight into the challenges and solutions within our field.

Hall and Zarrow are the driving forces behind ITM Consulting, where they help manufacturers around the world improve processes, solve complex problems, and build more reliable products. 

Whether it’s soldering, cleaning, reflow profiling, process control, or failure analysis, these two have seen it all, fixed it all, and taught it all.

In this episode, we tackle some of the most pressing issues facing the industry today, from the challenges of miniaturization, the reality of voiding, to the rise of electronics deployed into harsh environments, to IPC standards, and the role of process control in ensuring long-term reliability.

Whether you're a process engineer, a quality manager, or simply passionate about electronics manufacturing, this is a conversation you won’t want to miss.

RM 173: Reliability as a Service: How ChargerHelp! Keeps EV Charging Running

As the electric vehicle market accelerates, the reliability of the charging infrastructure becomes increasingly vital. Chargers that are down or malfunctioning can hinder adoption and erode consumer confidence. But who ensures these chargers stay up and running?

This episode of Reliability Matters dives into that very topic with a trailblazer in the EV service space. Our guest is Kameale Terry, cofounder and CEO of ChargerHelp!, a company revolutionizing how we think about EV charger maintenance and reliability. 

Under her leadership, ChargerHelp! has pioneered Reliability as a Service, developed a highly trained and diverse technician workforce, and shaped industry policies aimed at improving charger uptime.

Terry's journey is as inspiring as it is innovative, leading a national movement for a more reliable and equitable EV charging network. With backgrounds in workforce development, clean tech, and digital operations, she’s uniquely positioned to tackle the challenges facing this growing industry.

In this episode, we’ll explore the common causes of EV charger failures, the role data plays in predictive maintenance, the impact of new regulations like the National Electric Vehicle Infrastructure (NEVI) standards, and how ChargerHelp! is creating pathways into the clean energy economy for workers from all walks of life.

If you've ever wondered how reliability translates to the EV world, or how technology and workforce innovation go hand in hand, you won’t want to miss this conversation.

Chapters:

00:00:00 Revolutionizing EV Charger Reliability with Charger Help

00:02:14 Meet Camille Terry, Entrepreneur and Innovator

00:04:15 Starting ChargerHelp: A Journey from EV Connect to Entrepreneurship

00:06:16 The Impact of Pollution on EV Adoption

00:08:37 Understanding Reliability as a Service Model

00:10:35 Benefits of Reliability as a Service Model

00:12:40 Optimizing Asset Performance with Data Insights

00:14:56 Common Causes of EV Charger Failures

00:16:50 Reducing Mean Time to Repair in Software

00:18:47 Evolution of Memory Cost and Data Collection

00:21:06 Challenges in EV Charger Reliability and Failures

00:23:28 Emerging Leaders in European EV Infrastructure

00:25:37 Workforce Development in EV Infrastructure

00:27:42 Impact of California's EV Charging Reliability Act

00:29:20 Tesla Charging Stations: Leading Reliability Standards

00:31:42 Automotive Firmware Failures: Responsibility and Transparency

00:34:32 Planning for Robust System Configurations

00:36:33 Future Trends in the EV Charging Industry

00:37:36 The Rise of Charger and Smart Engineering

00:39:26 The Rise of Slate EV and Building Great Electric Vehicles

00:41:25 Human Connection in Technology

00:43:24 Importance of Profitability in Business Strategy

00:45:20 The Role of Cash in Business Operations

00:47:26 Conclusion and Podcast Schedule