PCB Chat

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.

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

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.

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. 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

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. 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

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.

Zachary Feuerstein founded his latest venture in 2022 after running into problems purchasing basic white goods and consumer electronics due to the post-Covid supply chain disruptions. That company, Breadboard, was officially launched with the very modest goal of revolutionizing the electronics supply chain management industry. Designed to automate and expedite BoM processing, optimize component spend, and automate quoting processes, the Breadboard platform now boasts more than 60 EMS customers. Feuerstein joins PCB Chat host Mike Buetow to explain the platform and his "Eureka" moment.

Just like the famous line from the 1984 film, The Terminator, “I’ll be back,” SMTAI is back. Back to the Chicago area. We’re back in Rosemont, co-located with the Assembly Show, at the Donald E. Stephens Convention Center, October 20-24. Between SMTAI and the Assembly Show, there will be thousands of engineers and industry professionals in attendance. The exhibit floor features hundreds of exhibitors showing off the latest technology. But the topic we're discussing today is the technical conference and other planned events taking place at this year’s SMTAI. This year, there are 11 scheduled professional development courses, about 100 technical presentations across seven technical tracks. Joining Mike Konrad to discuss what’s in store for attendees is Jason Keeping, member of the SMTA Board where he is vice president of technical programs for SMTA. Jeff Kennedy, past SMTA president and director of the Manufacturing Excellence track, and Robert Boguski, member of the SMTA board where he is VP of membership and director of the Test and Inspection track.

This episode of Reliability Matters features three interviews including: • Kimberly Fagan from PVA • Taylor Wagan from CETEC ERP • Neil Hubble from Akrometrix Recorded live in Anaheim, CA, during IPC Apex Expo.

Wally Rhines returns to give the latest data and analysis on the printed circuit board and MCM design software market, and the broader electronic design automation market. Rhines comments on the quarterly data released by the ESD Alliance, shifts in demand from India and China, seasonal buying trends, employment and more. This episode is sponsored by PCB Way, celebrating its 10th anniversary as a leading supplier in electronics manufacturing, known for high-quality PCB prototypes and assembly services.

The CHIPS Act has hogged much of the oxygen in the tech industry for the past few years, but the industry trade group known as the Printed Circuit Board Association of America is trying to build on that momentum by relentlessly pointing out that the board industry needs love too, or as they put it, chips don't float. With us today is David Schild, the executive director of the PCBAA. Schild and Mike Buetow discuss the prospects of pending Congressional legislation to support the US PCB industry, the need for domestic substrate and bare board production to complete the triad of the semiconductor "stack," and a just-announced Commerce Department plan to allocate up to $1.6 billion in funding to support the packaging supply chain.

Recorded live during IPC Apex Expo this spring, this is the first of three podcasts from the show floor. This episode features three interviews including: • Gus Mavrou from Seho • Mark Stansfield from Solderstar • Jesper Lykke from Viscom

The challenging world of electronics becomes even more challenging when the end product is destined for harsh environments. For high-reliability products operating in a harsh environment, the quest for reliability is not just a goal—it's an imperative. These are not your everyday gadgets; often they're critical components of systems designed to operate under extreme conditions, where failure is not an option. From the scorching heat of desert landscapes to the unyielding cold of arctic tundra, from the high-pressure depths of our oceans to the radiation-filled expanse of space, the demands on these electronic products are as varied as the environments themselves. While ocean depths, outer space, and frozen tundra are arguably harsh environments, we don’t have to look too far for examples of product failures in less harsh environments. One example that comes to mind is the state of public EV charging stations. Government reports have concluded that up to 25% of public EV chargers are at any given time. While there are many reasons for this, one may conclude they are not designed and manufactured for the intended in climactic operating environment. On this episode, we'll uncover the numerous challenges that designers and engineers face in their quest for reliability, durability, and functionality of the final product. As we navigate through this complex landscape, we'll highlight the strategies that enable these products to not just survive but excel in unforgiving conditions. Our navigator for this episode is, Dr. Andre Kleyner. Dr. Kleyner has 30 years of engineering, research, consulting, and managerial experience specializing in reliability of electronic and mechanical systems designed to operate in severe environments. He received a doctorate in mechanical engineering from the University of Maryland, and a master's of business administration from Ball State University. Dr. Kleyner is a Global Reliability Engineering Leader with Delphi Electronics & Safety and an adjunct professor at Purdue University. He is a Fellow of the American Society for Quality (ASQ), a Certified Reliability Engineer, Certified Quality Engineer, and a Six Sigma Black Belt. He also holds several US and foreign patents and authored multiple professional publications including two books on the topics of reliability, statistics, warranty management, and lifecycle cost analysis.

"Humans just aren't the greatest at designing circuit boards." That's according to Sergiy Nesterenko. Nesterenko is founder and CEO of a new software company called Quilter, whose goal is to accelerate hardware development by fully automating circuit board design. His eureka moment came when an early design at a previous employer couldn't be autorouted, then after it was hand-routed and built, it caught on fire. Listen to why the former Space X engineer thinks the margins designers build in are excessive and how AI-driven, physics-based platform can resolve and even violate some "human" rules and still generate superior printed circuit boards.

We’ve discussed the silver tsunami on the show numerous times, the unprecedented rate of which employees are retiring. When engineers and other employees retire from companies, they take with them more than a set of gold cufflinks or an engraved plaque. In many cases, they also take with them wisdom and knowledge. Perhaps this is never truer than in the case of Mike Konrad's guest today. And who is that? Doug Pauls. Pauls holds a B.A. in chemistry and physics from Carthage College, and a B.S. in electrical engineering from the University of Wisconsin, Madison. He worked nine years for the Navy, eight years as technical director of Contamination Studies Labs, and more than 20 years at Rockwell Collins (now Collins Aerospace), in the Advanced Operations Engineering group where he is a technical fellow and, a principal materials and process engineer. He was awarded the Rockwell Collins Arthur A. Collins Engineer of the Year Award in 2004 as well as numerous other awards. Paul is a longtime (well over 30 years) IPC chairman and was awarded the IPC’s Hall of Fame Award in 2017. Most notably, he is known for his expertise in surface insulation resistance testing, cleaning and cleanliness assessment, conformal coatings, and how to investigate and qualify manufacturing processes. He has been a U.S. representative to ISO and IEC working groups on SIR, electromigration, and cleanliness reliability standards. He has participated in numerous national and international consortia on electronics manufacturing materials and processes. He recently led a team of SMEs to redefine the cleanliness provisions of J-STD-001, culminating in what is presently J-STD-001H. To take liberties with a famous Mark Twain quote “rumors of my retirement have been greatly exaggerated”. For several years now, I’ve heard rumors of Pauls' retirement. Well, that day has finally come. Konrad talks with Pauls about his long career within the electronics assembly industry: his triumphs and challenges, and his journey in this ever-changing, dynamic, and challenging industry. If you’re new to this industry, stick around listen to Doug's advice to young people entering our world, the world of electronics assembly. 00:00:00 - Introduction to Doug Pauls' Career in the Electronic Assembly Industry 00:02:57 - Reliability Matters Podcast Introduction 00:06:04 - Sharing wisdom with early career individuals 00:09:34 - Hobbies Outside of Work 00:12:44 - The Minions and World Domination 00:16:23 - Overcoming Shyness through Theater and Public Speaking Lessons 00:19:41 - Lessons Learned from Skilled Trades People 00:23:03 - Working in the Department of the Navy 00:26:21 - Learning from Asking Questions and Trying New Things 00:29:38 - Learning from the Old Guys 00:33:05 - Participating in Standards Development 00:36:32 - The Power of Networking and Technical Committees 00:40:01 - The Value of Leadership Skills in Collaborative Industries 00:43:15 - Collaboration in the Electronics Industry 00:46:18 - Developing Valuable Skills in Problem-Solving 00:49:39 - Transitioning to Rockwell Collins 00:52:59 - The Four Pillars of Career Advancement at Collins Aerospace 00:56:32 - Finding Resources for Personal Growth 01:00:01 - Industry Updates and Resources 01:03:26 - The Value of Old Guy Stories 01:06:46 - The Importance of Understanding How Things are Made 01:10:08 - Retirement Plans, Consulting, and the Future 01:13:10 - An Unconventional Industry Presentation 01:15:59 - Thank You for Listening to the Reliability Matters Podcast

Businesses are not immune to the many complex social situations present on many prominent college campuses today. Executives and managers must grasp with how best to understand the changing environment as part of their talent acquisition and talent building processes, and implement those methods in practical ways to accommodate today's employees' life cycle. Audrey McGuckin is a global HR executive who for more than 25 years has lived and worked across the globe in Asia, Europe and the US. She spent more than 20 years at Jabil, rising to vice president and chief talent officer. Today, as head CEO of The McGuckin Group, McGuckin consults with top CEOs and CHROs to solve complex business challenges through innovative talent and people solutions. Her client base includes a broad spectrum ranging from startups to Fortune 100 organizations. She shares her thoughts and approach to business leadership, team building, managing employee movements and needs, and the power of empathy with PCB Chat host Mike Buetow.

This episode was recorded at SMTA's Pan Pacific Strategic Electronics Symposium on the Big Island of Hawaii. Mike Konrad's guests on this episode are Dr. Chuck Bauer, founder of PanPac, Keith Bryant, and Dr. Ron Lasky. We discussed the history of PanPac, technologies introduced at PanPac, and what makes PanPac so unique. We also discuss Dartmouth College's unique engineering innovations program. Chapters: 00:00:00 - Introduction to the Reliability Matters Podcast 00:01:35 - Introduction: Dr. Chuck Bower and Keith Bryant 00:03:23 - The Motivation Behind Starting IMAPS and SMTA 00:05:16 - Global Participation in the Event 00:07:25 - High Level Participants and Learning Experience 00:09:23 - The Conference of Interesting Things 00:11:01 - Speaking to the Thought Leaders of the Industry 00:12:40 - Preconceived Notions about the Event 00:14:26 - The Best Event for Networking and Fundamental Research 00:16:05 - Networking at Conferences 00:17:42 - The Advantage of Combining Innovation and Engineering 00:19:17 - Fostering Entrepreneurship among Students 00:20:57 - The Future of Young People 00:22:34 - Challenging Stereotypes about the New Generation 00:24:03 - Advice for Emerging Engineers and Technicians 00:27:17 - The Benefits of a Liberal Arts Education in Engineering 00:28:48 - Bringing Students to the Conference for Experience 00:30:11 - Entrepreneurship and Thinking Outside the Box 00:31:46 - The Value of Thinking like an Entrepreneur 00:33:22 - The Advantages of Ignorance in Starting a Business 00:34:51 - Throw caution to the wind and pursue your passions 00:36:25 - Appreciation and Thanks 00:37:49 - Stay Safe, Stay Happy, Stay Healthy

Optimization has become an important goal within the electronics assembly industry. While modern electronics assembly techniques utilize a variety of equipment, one specific type of equipment often consumes a disproportionate percentage of the overall equipment budget, that is the place machine. The cost of the machine, associated conveyors and feeders, require that the machine is running as often as possible. The airline industry refers to this as “wheels up” time. Airlines make money when the aircraft is in the air “wheels up.” On the other hand, anytime the wheels are down, the aircraft is not making money for the airline. I listened to an interview a few years ago with the CEO of Southwest Airlines, a US discount carrier. Unlike most other airlines, Southwest does not charge its customers to check bags. The CEO was asked by the reporter why they have not joined the rest of the industry in charging for checked bags. The CEO's answer was genius. If Southwest Airlines began charging for check bags, it would actually slow the boarding process as more and more passengers would drag their bags onto the aircraft, most likely resulting in a number of those bags having to be checked at the gate. Southwest Airlines is famous for having the fastest aircraft gate turns in the industry, frequently under 30 minutes. Yet, if Southwest Airlines charged for checked baggage, it would require more time at the gate before the next flight would be ready to depart. That would result in fewer flight segments per aircraft per day. In other words, allowing customers to check bags for free equates to more “wheels up” time and, subsequently, more profit for the airline. The same principal can apply to pick-and place machines. When pick-and-place machines are running product, they are making presumably making money. When they sit idle, they are arguably costing money. What can assemblers do to improve the optimization or “wheels up” time on their pick-and-place machines? Mike Konrad's guest, Larry Welk, believes he has an answer. Welk, a.k.a. Professor Splice, is coowner of Smart Splice, a manufacturer of tape splicing tools. Welk reviews tape splicing best practices and explain how tape splicing, when performed correctly, can lead to higher pick-and-place machine optimization. So, buckle your seatbelt: this podcast episode is officially wheels up! Chapters: 00:00:00 - The Importance of Optimization in Electronic Assembly 00:02:34 - Tape Splicing: Best Practices 00:05:12 - Tape Splicing and its Advantages in the Industry 00:07:42 - Continuous Tape Splicing 00:10:10 - Splicing Techniques in Machine Assembly 00:12:31 - Ensuring Quality and Reliability of Tape Splices 00:14:57 - The importance of alignment in splicing 00:17:21 - Types of Tapes and Their Impact on Splicing 00:19:54 - Challenges with Tape Splicing 00:22:09 - Adjusting Feeder Tension 00:24:25 - Splicing and Reel Management in the Industry 00:26:46 - Splicing Parts in the Electronics Industry 00:29:02 - Common Mistakes in Tape Splicing 00:31:34 - Issues with Tape Splicing 00:34:03 - The Crimping Tool and Tape Issues 00:36:25 - The Importance of Switching Techniques 00:38:53 - Improving Production Efficiency through Component Evaluation 00:41:44 - A demonstration of the old tape splicing method 00:44:08 - Splicing Tape Procedure Comparison 00:46:38 - Faster Splicing Technique 00:49:15 - The Negative Experiences with Splicing 00:51:55 - The Benefits of Splicing 00:54:22 - Transitioning from Technician to Salesman 00:56:40 - Conclusion and Farewell

Electronic System Design (ESD) industry revenue increased 14% to $4.4 billion in the fourth quarter 2023, with printed circuit board design software leading the way, up 21% for the period. Wally Rhines, executive sponsor of the SEMI Electronic Design Market Data report, gives his quarterly update on the state of the electronics design software market.

The High-Density Packaging User Group, the nonprofit consortium of electronics manufacturers and suppliers that collaborate on various technical problems in order to reduce cost and time to market, has nearly 25 projects underway, several of which are due to be completed this year. We spoke this month with Madan Jagernauth, marketing director and project facilitator of HDP, about their current research on lead-free solder alloys, the recent conference Best Papers, and whether the consortium members are ready to tackle artificial intelligence.

Today, we delve into an increasingly critical aspect of technology and electronics manufacturing - the pursuit of environmentally responsible electronics manufacturing. Our industry has witnessed many environmental revolutions. The elimination of popular cleaning solvents brought on by the Montreal Protocol in 1989, soon followed by strict VOC regulations pertaining to cleaning chemicals. The switch from lead-based solders to lead-free alloys, led by the Restriction of Hazardous Substances Directive, known as RoHS, implemented within the EU in 2003 and adopted nearly worldwide, regulations regarding the disposal of electronic waste (e-waste) resulting in many countries mandating regulations and programs for the safe recycling and disposal of electronic products, and more. These regulations and others have inspired some companies to seek eco-friendly alternatives to traditional printed circuit board (PCB) fabrication. The combination of numerous environmental regulations has resulted in many companies’ implementation of sustainability programs. As our world becomes more connected, the demand for electronic devices continues to rise, and with it, the importance of mitigating the environmental impact of their production. On this episode of The Reliability Matters Podcast, Mike Konrad speaks with Mark S. Edwards. Mark wrote an article entitled “Environmentally Responsible Alternatives to Traditional PCB Fabrication.” He works as a strategic account manager within MacDermid Alpha Electronics Solutions, on the global Business Development team for Circuitry Solutions. Mark has been involved in electronics manufacturing since the late 1980s and brings a passion for process automation, circuit assembly, solders/fluxes, adhesives, coatings and PCB fabrication – all with a focus on repeatability and reliability. Edwards holds a B.S. degree in mechanical engineering technology from Oklahoma State University and began his career at a defense electronics company in Dallas, Texas, that was later acquired by Raytheon. He has uncovered trends and synthesized customer needs for electronic hardware in the telecommunications, defense, automotive, industrial controls segments in the Americas, and now globally, in his newest role. Chapters: 00:00:00 - The Pursuit of Environmentally Responsible Electronics Manufacturing 00:02:23 - Uncovering Trends in Electronic Hardware 00:04:56 - Circuit Board Fabrication and Environmental Responsibility 00:07:25 - The Changing Priorities of the Manufacturing Industry 00:09:40 - Green Alternatives to Traditional Circuit Boards 00:11:59 - Sustainable Alternatives to PCB Fabrication 00:14:21 - Fabrication Performance and Reliability 00:16:43 - Green PCB Fabrication Challenges and Obstacles 00:18:58 - The Challenges of Adopting Greener Solutions 00:21:22 - Environmental Sustainability in the Supply Chain 00:23:43 - Environmental Impact of PCB Fabrication Methods 00:28:20 - The Disappointment of EV 85 Fuel 00:31:07 - The Cost Implication of Going Green 00:33:31 - Recycling and the Circular Economy 00:35:55 - Recycling Circuit Boards and Extracting Precious Metals 00:38:15 - Simplifying the PCB Fabrication Process 00:40:40 - The Importance of Standards and Regulations in the Electronics Industry 00:42:54 - Demand for Environmental Responsibility in PCB Fabrication 00:45:10 - The Importance of Sustainability in the Supply Chain 00:47:20 - The Importance of Sustainability in Circuit Assembly 00:49:49 - Environmental Impact of Board Fabrication 00:52:02 - The Green Movement in Business

Matthias Wagner is chief executive and cofounder of Flux, a developer of a browser-based PCB design platform and programmable simulator. When spoke with Matthias last spring, the company was introducing Flux Copilot, an AI-powered hardware design assistant. Flux Copilot uses a large language model that the company’s engineers trained and integrated into its design tool. Flux recently added vision capability to its signature tool, whereby users can upload photos of images such as block diagrams to CoPilot and it can recommend parts for their design. This week, we talk about those advances, some real-use cases Flux is seeing, the Renesas-Altium merger, and more.

Today we're diving deep into the world of precision and craftsmanship—two crucial elements in the realm of hand soldering and rework of circuit assemblies. Whether you're a seasoned electronics enthusiast, a hobbyist, or just someone with a curious mind, this episode promises to demystify the art and science behind hand soldering and rework. We'll be exploring the latest tools, techniques, and trends that define this intricate process, shedding light on the unsung heroes who meticulously bring circuit assemblies to life, or in the case of rework, back to life. There is archaeological evidence that soldering was employed as early as 5,000 years ago in Mesopotamia. Soldering and brazing are thought to have originated very early in the history of metal-working, before 4,000 BC. Sumerian swords from 3,000 BC were assembled using hard soldering techniques. While soldering applications have morphed and expanded over the centuries, the basic “rules” of soldering have not. On this episode, we’re going to talk about an obvious soldering application, at least to my audience, and that’s soldering of electronic assemblies. From the evolution of hand soldering with numerous technological advancements to the challenges faced by DIYers and professionals alike, we've got it all covered, thanks to Mike Konrad's subject matter expert guest, Debbie Wade. Wade is managing director of ART A-R-T, Advanced Rework Technology, a fully independent training organization, which has been presenting various training courses for over 30 years. She has been in the electronics industry for over 20 years with the last 15 of those years at Advanced Rework Technology. Wade comes to us well-credentialed. She chairs the IPC-A-620 Training Committee and IPC European Training Committee, and with her Master IPC Trainer status for IPC-A 600, 610, 620, 7711/21 and J-STD 001 is an expert in the field of fabrication, assembly, process and acceptance of board and cable assemblies. She has been presented with numerous awards from IPC in recognition of her contribution to IPC standards and training courses. So, grab your soldering iron (metaphorically speaking), get ready to dive into the flux, and join us as we unravel the secrets of successful hand soldering and rework. Stick around for valuable insights, practical tips, and maybe even a few stories from the trenches of hand soldering and re-work. Chapters: 00:00:00 - The Art and Science of Hand Soldering and Rework 00:03:01 - The Unique Art of Hand Soldering, Featuring Debbie Wade 00:06:30 - The History of Advanced Rework Technology (ART) 00:09:57 - The Impact of IPC Certification on Careers and Companies 00:13:14 - Investing in the Right Equipment for Soldering and Rework 00:16:22 - Controlling Heat in Soldering 00:19:24 - Creating the Heat Bridge 00:22:29 - Challenges in Soldering Electronic Components 00:25:39 - The Dangers of Using Soldering Guns for Electronics 00:28:32 - Common Mistakes in Hand Soldering 00:31:42 - The Importance of Flux in Soldering 00:34:38 - Proper Flux Application and Potential Issues 00:37:35 - The Problem of Flux Buildup on Test Points 00:40:50 - Appearance vs Function in Solder Joints 00:43:42 - Choosing the Right Soldering Iron 00:46:55 - Safety Precautions in Hand Soldering 00:49:50 - Appearance and Plating Issues 00:52:48 - Inspecting Different Classes of Products 00:55:39 - The importance of human control in machine programming 00:58:45 - Bespoke courses and certifications for inspectors 01:02:01 - The Importance of Proper Component Selection and Soldering 01:05:09 - Differences in Soldering Dummy Parts 01:08:04 - The Art of Hand Soldering 01:10:55 - The Importance of Reliability

Today, we delve into the crucial aspects of maintaining well-being on this journey — how to sidestep the notorious burnout, and perhaps more importantly, how to fuel and maintain your motivation. Because, let's face it, the road to creating a meaningful impact can be demanding, and it's essential to navigate it with resilience and purpose. Join Mike Konrad for a conversation with Rick Coulson. Rick recently retired from a 34-year career at Intel, most recently as senior fellow in the Intel Optane Group. Coulson is a passionate advocate for career sustainability and for servant leadership. He was awarded the Intel Achievement Award four times for his team's work on storage subsystems and SSD technology. He holds more than 90 patents. Coulson has a bachelor's in electrical engineering and computer science from the University of Colorado and a master's in electrical engineering from Stanford. He is currently a board member at Co-Serve International, a nonprofit dedicated to teaching Servant Leadership around the world. With Co-Serve he has been to Kazakhstan eight times. He’s on the advisory board of Vooks, a company which produces award-winning books that are loved by parents and educators alike, and he’s part of an additional stealth mode startup (sounds mysterious). He enjoys mentoring and coaching.

We welcome back one of our favorite guests, David Schild, the executive director of the Printed Circuit Board Association of America. PCBAA was founded about three years ago to advance US domestic production of PCBs and base materials. The organization is made up of corporate members of all sizes, and includes fabricators, assemblers and suppliers. Schild brings us up to date on the US Department of Defense's National Defense Industrial Strategy, how industrial production is tied to military readiness; the House Select Committee on the Strategic Competition Between the United States and the Chinese Communist Party's December 2023 report on how to staunch the flow of IP offshore and rekindle tech leadership and economic resilience; and whether the US government plans to get into the manufacturing business.

Artificial intelligence is perhaps the most discussed – and least understood – topic in technology today. We in electronics design and manufacturing know, of course, that automation is part and parcel of what we do. But while the landscape has changed, be it the transition from mechanical drawings to CAD tools with their autorouters, or from manual and semi-automatic printers and placement machines to lights-out factories where cobots have replaced operators, the industry still has a long, long way to go in terms of widespread implementation of AI, or even understanding what it all means. Andrew Scheuermann joins Mike Buetow to share some perspective on this emerging technology. Scheuermann, along with his business partner Tim Burke, is cofounder and CEO of Arch Systems, a Silicon Valley-based developer of software tools that collect raw machine data and use predictive analytics to calculate manufacturing key performance indicators, or KPIs. Scheuermann has published numerous scientific papers in the areas of semiconductors, electronics manufacturing, and renewable energy. He has a Ph.D. in Materials Science from Stanford, and is also part of StartX, a startup accelerator for company founders who are affiliated with Stanford that has invested over $200 million across various companies, including 13 now valued over $1 billion.

Reliability Matters covered the topic of ultrathin conformal coatings back in November. We covered various conformal coating materials from traditional acrylics and silicones to ultrathin parylene coatings. What other coating materials are available? Where do these types of coatings fit within specific applications? Where do health and safety, environmental concerns, and sustainability programs fit in with a coating process? To answer these other questions, Dr. Cassandra Zentner, VP of Health and environment at Actnano, a manufacturer of coating materials, talks with Reliability Matters host Mike Konrad. Dr. Zentner earned a BA from Oberlin College and a Ph.D. in organic materials chemistry from MIT.

EMA Design Automation has for years been the exclusive distributor of OrCAD Cadence in North America. Through acquisitions and internal development, EMA now has a series of its own software products for library management, component supply chain data. And this year EMA announced it would spin off those CAD-agnostic products into a new subsidiary called Accelerated Designs. EMA president and founder Manny Marcano joins Mike Buetow to break down the thinking behind the new company, its products, management and distribution agreement, and gives his take on Cadence's thoughts.

Printed circuit board and multichip module design software revenue soared 24% year-over-year to a record $426 million in the third quarter 2023, according to the ESD Alliance's latest Electronic Design Market Data (EDMD) report. ESD Alliance spokesperson Wally Rhines joins Mike Buetow to explain the latest data trends.

In today's increasingly connected and digital world, PCBs are the unsung heroes that power our devices, from smartphones to spacecraft. Yet, the art and science of designing these crucial components often go unnoticed. That’s where this episode comes in. Today, we shine a spotlight on the critical role PCBs play in modern technology and explore the best practices that drive innovation and reliability. In this episode, Mike Konrad tries to unravel the mysteries of PCB design, tackle complex challenges, and unlock the secrets to creating high-performance, efficient, and reliable circuit boards. Whether you're a seasoned PCB designer looking to sharpen your skills, a budding engineer eager to learn the ropes, or simply a tech enthusiast curious about the technology that shapes our lives, this episode has something for everyone. He is joined by Dr. Zach Peterson. Zach is a well-known researcher and electronics designer. In 2017, he founded Northwest Engineering Solutions as a technology consultancy and has since grown the company into an innovative design and manufacturing house for advanced electronic products. He conducted his Applied Physics Ph.D. research in ZnO random laser theory and stability and his M.Sc. Physics research in chemisorptive sensors for environmental monitoring at Portland State University. He also received his MBA (Leadership & Finance) from Adams State University. His work has been published in over a dozen peer-reviewed journals and conference proceedings, and he has written 2500+ technical articles on PCB design for a number of companies. He is a member of IEEE Photonics Society, IEEE Electronics Packaging Society, American Physical Society, and the Printed Circuit Engineering Association (PCEA). He previously served as a voting member on the INCITS Quantum Computing Technical Advisory Committee working on technical standards for quantum electronics, and he currently serves on the IEEE P31-86 Working Group focused on Port Interface Representing Photonic Signals Using SPICE-class Circuit Simulators. He will speak on Signal Integrity in Thin PCB Materials and IC Substrates at PCB East in June.

Episode 134 - 2023 Podcast Season Wrap-Up On this episode, I have no guests as this is the final episode of the Reliability Matters Podcast for the 2023 season. Instead, let's review what happened on the podcast this year. A special thanks to my guests and listeners/viewers for making this podcast so successful. Chapters: 00:00:00 - Introduction to Reliability Matters Podcast 00:00:12 - The Electronic Assembly Industry Techniques 00:00:26 - Review of the 2023 Season 00:00:43 - Liquid Metal in Electronic Circuits 00:00:56 - Instant Solidification of Liquid Metal 00:01:14 - Counterfeit Component Detection 00:01:31 - Making Sense of Big Data in the Electronic Assembly Space 00:01:49 - IPC Apex Expo: Supply Chain Challenges 00:02:07 - Circuit Assembly Failures and Big Data Analysis 00:02:22 - Interview with David Raby on High Liability Contract Manufacturing 00:02:37 - Training for Effective and Entertaining Reliability 00:02:53 - "Fire Your Hiring Habits" with President and CEO of IPC 00:03:08 - Introduction to Highly Accelerated Life Testing 00:03:25 - 3,600 Mile Solo Kayak Journey Down the Missouri River 00:03:42 - Moisture Mitigation Best Practices 00:03:59 - Life as a Technical Consultant 00:04:14 - Network Reliability and Cybersecurity Threats 00:04:30 - Innovative Approaches to Education and Industry Icons 00:04:46 - Conformal Coating Materials with Lisa Rizzo 00:05:01 - Introduction to Wireless Wearable ESD Monitoring Device 00:05:16 - The Reliability of Circuit Assemblies 00:05:32 - Reliability of Circuit Assemblies and Emerging Technologies 00:05:47 - Increasing Challenges in Electronics Engineering 00:05:59 - The Silver Tsunami and Retirement 00:06:31 - Motivation for Starting the Podcast 00:06:45 - Gratitude for Support and Encouragement 00:06:59 - Gratitude for the Subject Matter Experts 07:13:00 - Acknowledging EMS Industry Experts 00:07:27 - Subscribe to the Podcast or YouTube Channel 00:07:39 - Release Schedule 00:07:55 - PCB Chat and Accendo Reliability 00:08:11 - Suggestions and Contact Information 00:08:26 - Wishing You a Joyous Holiday Season

We are all aware of the damage electrostatic discharge can wreak on components and electronic products. We mitigate ESD damage through various forms of monitoring. We wear wrist and heel straps, stand on ESD-safe flooring, utilize ESD workstations, and more. We even have ESD testing locations that will test a human standing on a specialized testing station. But what happens the moment that person steps off the tester? My guests today are Dr. Daan Stevenson and Dr. Jonathan Tapson of IONA Tech, a manufacturer of a novel wearable ESD monitoring device that provides constant real-time ESD monitoring. Normally, we don’t talk about specific products on the show. We usually limit our conversations to best practices. This is a bit of an exception to rule. From time to time, a product is introduced that is so novel, it's worthy of a conversation. And that’s the case here. Dr. Daan Stevenson is chief executive officer of IONA Tech. Dr. Stevenson has a background in mechanical and aerospace engineering. During his doctoral research, he studied the high voltage charging of spacecraft, which are electrical capacitors in the same way that the human body is. While working to design an automated ground station for UAVs, he frequently damaged electrical components from electrostatic shocks. This motivated the creation of IONA Tech, with the goal of advancing technology in ESD mitigation. Our other guest is Dr. Jonathan Tapson, chief technology officer of IONA Tech. Dr. Tapson was professor of electrical engineering at Western Sydney University before moving to Colorado in 2016. He spent his early career conducting sensor and instrumentation research, with a strong industrial focus. During this time he spun out three companies from his research, all of which are successful today. His specialties include low-noise circuits and systems design, mechatronic design and the integration of machine learning into real-time systems.

David Schild is executive director of the Printed Circuit Board Association of America. PCBAA was founded in 2021 to advance US domestic production of PCBs and base materials. We discuss major investment announcements by US PCB companies, industry funding from the Defense Appropriations Subcommittee, the need for intense engagement at every level of government, and the latest on the Protecting Printed Circuit Boards and Substrates Act of 2023.

Robert Feranec is a hardware designer with over 20 years’ experience in the electronics industry, and specializes in PCB design, signal integrity and high-speed digital design. In addition, he is also a self-described passionate content creator on YouTube, where he has developed a large series of help-guides for PCB design and electronics engineering. His company, FEDEVEL Academy, also provides courses on electronics design. We talk about autorouting, simulation tools and teaching board design concepts on this edition of PCB Chat.

Today we’ll dive deep into the world of conformal coating. More and more assemblies are being subjected to conformal coating to protect the assembly from harsh environments. What’s leading the drive to conformal coat electronics assemblies? What types of conformal coating options are available? What are the advantages and disadvantages of each type? For circuit assemblies, the protective embrace of conformal coatings ensures reliability, longevity, and performance. As technologies advance, so does the demand for innovative solutions to safeguard our electronic products. Whether you're a seasoned industry professional, a curious tech enthusiast, or just someone who's new to the world of conformal coatings, this episode is your go-to source for in-depth information on the growing trend of applying conformal coating to circuit assemblies. So, join us as we peel back the layers, and immerse ourselves in the world of electronics protection, and learn how conformal coatings play a pivotal role in keeping our devices humming, even in the harshest environments. To better understand conformal coating, I invited Lisa Rizzo to the show. Rizzo is Senior Director of Strategy & Emerging Applications at HZO. HZO is a global leader and innovator in protective solutions that, according to them, “keep the world running.” They provide products to markets including consumer electronics as well as high-reliability markets including automotive, industrial, medical, and IoT to deliver a more resilient, reliable, and durable level of protection. HZO specializes in nanocoating solutions that safeguard electronics, electrical products & critical applications in an ever-changing market.

We are all aware of the supply chain issues our industry has faced. Beginning with electronic components, it has spread to so many other types of parts are industry relies on. Fortunately, it looks like we are beginning to come out the other end of the supply chain shortage. But the supply chain problems have further spread to the labor market. If you are in a position to hire people for your company, you know firsthand how difficult that process can be today. Adding to the level of labor acquisition difficulties is the great “Silver Tsunami,” otherwise known as the great retirement. As mentioned on Reliability Matters episode 130, the fact is, Baby Boomers are entering retirement in greater numbers. According to government data, from now until 2030, 10,000 boomers will hit retirement age each day. Millions will begin to officially retire. Some of these retirees are designated subject matter experts within their companies. Not only are people retiring, they are taking with them a vault of valuable knowledge. This has created an even larger demand for consultants within our industry. I’ve had several industry consultants on my show over the last few years, including today’s guest: legendary industry consultant, Bob Willis. If you’ve been in this industry longer than 18 seconds, there’s a good chance you’ve at least heard his name. If you’ve been in this industry for virtually any length of time, there’s a good chance you’ve seen his videos, read his books, or watched him present at numerous industry conferences and symposiums. If I reviewed Bob’s complete professional biography, it would take an entire episode. During our conversation, we discussed Bob's newest book, Robotic Soldering Inspection and Defect Guide. Anyone who makes a donation to Bob's chosen charity will receive a download of his book as well as access to Bob's complete book collection: Robotic Soldering Inspection and Defect Guide Pin in Hole Intrusive Reflow Desing Assembly & Defect Guide Package On Package Assembly Inspection & Quality Control Solder Paste Print Inspection & Defect Guide Lead-Free Defect Guide 3 Conformal Coating Inspection & Defect Guide QFN LGA Assembly Inspection & Defect Guide PCB Surface Finishes Inspection & Defect Guide Cleaning & Contamination Defect Guide Click the following link for more information: https://www.justgiving.com/page/bob-willis-roboticsolderingbook

Printed circuit board and multichip module design software revenue increased 6.3% in the second quarter to total $369 million, according to the ESD Alliance's latest Electronic Design Market Data (EDMD) report. The four-quarter moving average for PCB and MCM, which compares the most recent four quarters to the prior four, rose 11.7%. As a whole, ESD industry revenue increased 5.3% to $3.96 billion in the second quarter from $3.76 billion in the second quarter of 2022. The four-quarter moving average rose 9.5%. Wally Rhines joins Mike Buetow to explain the latest data trends.

Baby Boomers are entering retirement in greater numbers. From now until 2030, 10,000 Boomers each day will hit retirement age. Millions will begin to officially retire. This is creating a terrific opportunity for young college graduates to enter our industry. Several years ago, I was a speaker at the SMTA, Pan Pacific Strategic Electronics Symposium in Hawaii. I shared my breakfast table with a longtime colleague, Dr. Ron Lasky, a professor at Dartmouth College. Over the course of breakfast, he asked me how I got into this industry and, more specifically, how I started my company. Dr. Lasky is an engineering professor at Dartmouth’s Thayer School of Engineering. He also teaches entrepreneurship to his soon to be engineers. Dr. Lasky invited me to come speak to his students. I was more than happy to take him up on his offer, and I have spoken to his students on the subject of entrepreneurship every year for the past several years. I have been impressed by the emphasis on entrepreneurship within the Thayer School of Engineering. We live in a time of marvelous evolution within the electronics space. So many new and innovative electronic products are being introduced, fueled by IoT (Internet of Things), the electrification of automobiles, advances in communication, and so much more. Education is the bedrock of our industry. It is the foundation for which much of our industry and the products we make are built upon. I’ve had Dr. Lasky on my show several times, and I thought it would be a great idea to invite his boss, the dean of Dartmouth’s Thayer School of Engineering, onto the program. Dr. Alexis Abramson is the 13th dean of the Thayer School. Prior to joining Dartmouth, she was the Milton and Tamar Maltz Professor of Energy Innovation at Case Western Reserve University and served as a director of the university’s Great Lakes Energy Institute focused on creating sustainable energy technology solutions. During the Obama administration, Dr. Abramson served as chief scientist and manager of the Emerging Technologies Division at the US Department of Energy’s Building Technologies Program. In 2018, she served as technical adviser for Breakthrough Energy Ventures, a $1 billion effort launched by Bill Gates to combat human-driven climate change. Dr. Abramson’s research has focused on novel techniques for thermal characterization of nanostructures, the design and synthesis of unique nanomaterials for use in alternative energy applications, virtual energy audits for building energy efficiency, and strategies to accelerate technology commercialization at universities and research institutions. Dr. Abramson earned a bachelor's and master's in mechanical engineering from Tufts University and a Ph.D. in mechanical engineering at the University of California, Berkeley.

The Reliability Matters podcast is almost exclusively about reliability. Specifically, reliability of circuit assemblies. We discuss production best practices, design for manufacturing and reliability. Failure analysis, and more. We’ve reviewed the latest trends in industry 4.0, the connectivity of machine to machine and machine to management. We discussed big data and how to make all of our newly acquired data relevant and actionable. For all this to occur, our computers must function properly. They must perform the assigned tasks and communicate large sums of data. What happens to our production line if the computers stop functioning? What would happen if our network ceases to operate? We’ve all witnessed the airline industry grind to a halt recently due to computer failures and connectivity issues. The fact is, very few industries can function properly or even at all if the computer systems fail. I’m not referring to quality issues within the computer or network’s internal circuit assemblies. I’m referring to malware, ransomware, and other nefarious actions brought on hackers with the intent to disrupt companies, industries, and governments, frequently with the goal of returning (or promising to return) your own data in exchange for an exorbitant payment. Our industry, like many others is completely dependent on computers and connectivity. Without ether, most production lines will simply sit idle. How can we avoid this terrifying scenario? How do hackers gain access to our computers and networks? How can we add reliability to our computer and network policies and procedures? To answer these and other related questions, we talked with network security expert Adrian Francoz, cofounder and CEO of Zeta Sky, a managed IT support and cybersecurity services company lives in the world of cyber security. He and his company protect their customer’s networks through the implementation of security best practices and constant training, both for his customers, and for his own staff. After all, hackers and other bad actors are hard at work searching for the next scam, vulnerability, and the opportunity to score a huge payday, all at our expense. In the Southern California area? Consider attending the inland Empire cybersecurity summit on Thursday, October 26 at the Chaffey College InTech Center, 9400 Cherry Ave, Bldg A Fontana, CA 92335. Register here: https://www.zetasky.com/inland-empire-cyber-security-summit-2023

HDP User Group is an industry consortium made up of more than 50 leading companies that collaborate on research in order to reduce cost and time to market. Madan Jagernauth, marketing director and a project facilitator, discusses recently completed programs on low silver solder paste reliability, copper surface roughness models, the Pb-Free bare board materials project updates, and HDP's upcoming meeting in October with PCB Chat's Mike Buetow.

In recent episodes, we’ve covered high-level issues, such as hiring best practices, novel, training, methods, design for manufacturing, highly accelerated, life, testing, and more. On this episode, we’re going to go back to the basics. What common problems are assemblers experiencing today? What are the basics of assembly best practices? Which problems seem to live in perpetuity? To answer these and other questions, I’ve invited two of my favorite experts on to the show. If you’ve been in the electronics assembly industry for some amount of time, there’s little doubt you’ve heard of Phil Zarrow and Jim Hall. Phil has been involved with PCB fabrication and assembly for more than 36 years. He is president and principal consultant of ITM Consulting. Jim Hall has been involved in the electronics assembly industry for the past 27 years. He’s a principal consultant and resident Lean Six Sigma Master Black Belt with ITM Consulting. He’s also an instructor in the Lean Six Sigma programs offered at Dartmouth College. Together with Dr. Ron Lasky, Phil and Jim designed the SMTA’s SMT Processes Certification Course. A couple of years ago, Phil and Jim published a book titled “Troubleshooting Electronic Assemblies, Tales from the Board-Talk Crypt.” Mike Konrad talks to them more about that book later in this broadcast. Phil and Jim host the popular audio series “Board Talk,” a question-and-answer show hosted on the Circuit-Insight website. On their show, you’ll hear serious questions, and often comical but real answers.

Moisture. The industrial world has been fighting moisture since the beginning of the industrial world. From a general point of view, moisture leads to issues such as Mold and mildew Rust Wood rot Damage to building materials Microbial growth And so much more. In the electronics world, moisture creates a host of reliability problems including: Popcorning Delamination of conformal coating Corrosion Electrochemical migration Adhesion degradation (such as on labels and glues) And more. We wanted to dive into moisture mitigation, so Mike Konrad invited two guests to discuss this very topic. Dan Jenkins is sales manager and partner of the Steel Camel, an industrial solutions company specializing in corrosion and water intrusion control for fuel systems and industrial equipment. Prior to Steel Camel, Dan worked as consultant and instructor in the crane accident prevention industry. He has consulted to large organizations such as Shell Oil, and the United States Department of Interior. Dan earned an MBA from the University of South Florida and earned his BA in Industrial Arts / Technology from Cal St. University Chico and his Post-Secondary Teaching Credential from San Francisco State University. Bob Lowry has bachelor's and master's degrees in chemistry. His experience includes 31 years as sr. scientist and lab manager for three integrated circuit manufacturing companies, where measurement of moisture and moisture control activities were a major part of services he provided. He has 20 years of experience consulting to the microelectronics industry on a wide variety of topics including materials analysis and measurements and methods of moisture control for electronic components. Bob is also coauthor of the book Hermeticity of Electronic Packages. Dan Jenkins' contact info: [email protected] https://www.steelcamel.com/ Bob Lowry's contact info: [email protected]

As all of you are well aware, Reliability Matters is all about reliability, specifically reliability of circuit assemblies. One challenge that seems to be persistent within our space is design for manufacturability, or DfM. If you’re a contract manufacturer, no doubt you’ve had the experience of being asked to build a product that seems unbuildable. One example that rings true was the introduction of bottom terminated components or BTCs. BTC’s are marvelous components. Because all the lead terminations are below the part, they permit highly dense component placement and highly miniaturized assemblies. They also presented a number of unique challenges in reflow, in many cases voiding, cleaning, and inspection. Like many other industries, we are not immune to the introduction of new technologies that may lack implementation knowledge. We then spend the next several years at technical conferences and symposiums learning us how to implement these new technologies. There are many acronyms in our industry that begin with Df… Design for testability, mechanical assembly, serviceability, reliability, and so many more. So many in fact, that there is a placeholder acronym for all of the various design fours refer to as DFx. Perhaps the holy grail of DFx is DfM (design for manufacturability) as it encompasses so many aspects of assembly. Today Andrew Williams helps us understand what exactly DFM is. He is engineering manager for electronics manufacturing at PRIDE Industries. He has more than 30 years of experience in manufacturing and design and holds an SMT Process Engineer certification from SMTA and an IPC Certified Electronics Program Manager. He is a guest lecturer at UC Davis and Cal State University Sacramento for Supply Chain Management, Operations, and TQM courses, and speaks frequently on DfM, DfS, and other DfX topics.

Industry icon Dave Hillman completed a 3,600 mile solo kayak journey down the Missouri River. Mike Konrad spoke with Dave about the inspiration for the journey, insights gained over his four-month expedition, and how his experience as an engineer helped him prepare for this epic experience. This episode features many photographs taken by Dave Hillman on his journey. The video version showing the photographs is accessible here: https://youtu.be/7bThR5FQwHI

David Schild, executive director of the Printed Circuit Board Association of America (PCBAA), discusses the latest government policy and legislation for printed circuit board manufacturing in the US, the roadmap for government investment, the trade group's recent annual meeting in Washington, and "exposing the flaw" in the US Defense Department's procurement process. PCBAA was founded in 2021 to advance US domestic production of PCBs and base materials. The organization is made up of corporate members of all sizes, and includes fabricators, assemblers and suppliers. This episode of PCB Chat is sponsored by PCB West, The Largest Conference and Exhibition for Printed Circuit Board Design, Fabrication and Assembly in the Silicon Valley, coming September 19-22 to the Santa Clara (CA) Convention Center.

Thermal interface materials are used for heat transfer in a variety of electronics applications. On this episode of PCB Chat, Claire Wemp, Ph.D, a thermal applications engineer at DuPont, discusses TIM1 materials (and explains the difference between TIM1 and TIM2), when and where they are used, who specifies them, and how they work. Wemp is also a member of the Society Women in Electronics, and in the second half of the podcast we talk about her experience in SWE, which dates to college, DuPont's role in recruiting, and how to bend the curve in attracting more women to STEM fields.

We all strive to build products that are reliable. If you’re listening to this podcast, chances are you are concerned about or at least interested in reliability. Where does reliability start? Who is responsible for reliability? What types of reliability testing can be performed? Mike Konrad's guest on this episode will help answer these and other reliability-based questions. Dr. Christopher Jackson is a leader, engineer and logistic specialist who has helped many organizations work toward realizing business goals through improving the reliability of their products and processes. He is cofounder of online training company IS4, founder of Acuitis Reliability, established the Center for the Safety and Reliability of Autonomous Systems (SARAS) at UCLA after retiring as a lieutenant colonel having served 17 years in the Australian Army, where he was senior reliability engineer. Dr Jackson completed his Ph.D. in reliability engineering at the University of Maryland in 2011. Dr. Jackson has authored multiple reliability and management textbooks and teaches both professional education courses and post-graduate courses. Industries he has helped range from small satellites through to military vehicles. He is a Certified Reliability Engineer (CRE) through the American Society of Quality (ASQ), a member of the Institute of Engineers, Australia (MIEAust) and a Chartered Professional Engineer (CPEng). Dr. Jackson's contact information: [email protected] https://www.acuitas.com