PCB Chat

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

The PCB/MCM design software market grew in the first quarter 2023, the ninth straight quarter of growth, according to the latest data from the ESD Alliance. Mike Buetow speaks with Wally Rhines, ESD Alliance spokesperson, and Merlyn Bruncken, market intelligence director with Siemens Digital Industries, about the record quarter, booming employment in the sector, and why the recovery in Japan be lagging the rest of the world.

When it comes to circuit assemblies, defects result in one of two situations. The preferred result of a defect is to capture it on your factory floor and repair it before it ships to the customer. The second scenario is referred to as an escape. That’s when the board ships to the customer and fails in the field. This is a scenario, all assemblers dread and strive to prevent. One way to prevent escapes is through the use of automated inspection or AOI systems. Mike Konrad's guests are Arif Virani, chief operating officer and cofounder of Darwin AI, and Bart Piwowar, CTO of Darwin AI, a manufacturer of innovative inspection systems. Virani is a technology leader with over 20 years of experience in the industry. He spearheads the company’s mission to transform manufacturing with a new standard for quality inspection using AI. DarwinAI’s solutions have been implemented at top electronics manufacturers to increase quality and efficiency while reducing waste. DarwinAI was selected by CBInsights for its AI 100 annual list of the 100 most promising private AI companies in the world in both 2020 and 2021. Before founding DarwinAI, Virani had a successful career in management consulting at McKinsey & Co., where he advised Fortune 500 enterprises on technology investments and transformation. He led several technology-enabled programs, including building and commercializing data and analytics capabilities. Virani started his career working as a software developer at various technology companies. In addition to his work at DarwinAI, Virani is an Advisory Board Member of NGEN Canada’s AI for Manufacturing Initiative. He has a master’s in business administration from the University of Pennsylvania’s Wharton School and a bachelor’s in applied science (computer engineering) from the University of Waterloo. Piwowar is an experienced product leader, leading high-performing product teams driven by data to deliver solutions that solve customer's problems. He has spent many years leading data science teams, applying Innovation methodologies, and working with emerging technologies to bring solutions in many disciplines. He graduated from University of Waterloo with a degree in physics and computing and followed with an MBA from Wilfrid Laurier University. Piwowar's career interests range from AI product development, decision science and entrepreneurship.

It goes without saying finding talent is a big deal in electronics design and manufacturing. John Watson is customer success manager at Altium, with more than 20 years' experience as a senior PCB designer. Watson also teaches classes on printed circuit design at Palomar Community College in San Marcos, CA. We discuss the Printed Circuit Board Design and Advanced Printed Circuit Board Design curricula, other related courses offered at Palomar, and why he emphasizes hand routing over autorouting. Palomar's website is palomar.edu. Watson may be reached at [email protected] or 619-886-8860. Watson will also participate on the Next-Generation Engineers panel at PCB West this year. The conference takes place Sept. 19-22, at the Santa Clara CA Convention Center. The panel takes place on Sept. 20, same day as the exhibition, and is free to attend; register at pcbwest.com.

Can reliability training be both entertaining and effective? The Manufacturing Game's Michelle Ledet Henley has a different approach to traditional training methods. Henley has worked with The Manufacturing Game since 1998 as a developer of new simulations and training material. She has traveled worldwide in her capacity as a facilitator and trainer for The Manufacturing Game and other simulations developed by Ledet Enterprises. Henley has been instrumental in developing simulations with a focus on reliability, project management and distribution. She began her career with KPMG Peat Marwick in San Francisco, and then worked for a real estate management and development firm in the Washington, DC area. Before joining The Manufacturing Game, Henley formed her own company, Innovative Interfaces, which provides computer programming services around the United States. Henley has a bachelor's of business administration degree from the University of Texas - Austin in accounting and information services.

Mike Konrad's guest is Dr. James Whitfield. Dr. Whitfield is an associate professor of physics at Dartmouth. He earned a bachelor's of science and chemistry and mathematics from Morehouse University and a Ph.D. in chemical physics from Harvard University. He was a postdoctoral fellow at Columbia University in New York, Vienna Center for Quantum Science and Technology in Vienna and Gant University and Belgium, and he is currently an Amazon visiting academic.

Wally Rhines, the former chairman of Mentor Graphics and now spokesperson for the ESD Alliance, updates us on the latest PCB design software and semiconductor market trends (spoiler alert: sales were up again), and addresses why ECAD companies are hiring even in the face of layoffs among Big Tech. He is joined by Merlyn Brunken, director of marketing strategic planning at Siemens Digital Industries Software to provide the quarterly report, which showed gains across a number of sectors and geographies.

Flux says every step of the electronic design process is slow, expensive, and error-prone. The startup company’s engineers think they have a solution: a browser-based PCB design platform and programmable simulator. Matthias Wagner, CEO and cofounder, and Kerry Chayka, product expert, both veterans of PCB design with companies like Facebook and Apple, discuss the problems that led them to develop an all-encompassing tool that includes a programmable SPICE simulator for testing circuits with real parts and environments.

The subjects of Industry 4.0 and Big Data have been widely discussed on this podcast. What is Industry 4.0? What data is our industry collecting? And, perhaps more importantly, how can we sift through all of that data to make it useful and actionable? To help answer these and other data-related questions, Mike Konrad interviews Ryan Gamble, CEO and Founder of Intraratio. Intraratio is a company that provides on-premise and cloud hybrid software with platforms to track, manage, control, and automate the manufacture of advanced electronics. Intraratio serves the semiconductor, SMT, space/military, medical device and EV markets. Ryan earned a dual electrical and computer engineering degree and spent many years in the semiconductor industry. He’s responsible for improving product manufacturing and testing of commercial and space/military product lines including multi-core DSP, RF and silicon photonics devices. During this period he developed software systems to automate and manage quality and reliability of complex electronics, extending this to hyperscale web-based platforms that interconnect factories globally. His passion is working with all levels, to identify and recommend solutions to business problems, based on a deep technical understanding of operational processes and product complexities.

Eric Camden (lead investigator with Foresite) and Mike Konrad discuss electrochemical migration (ECM) and other failure modes caused by residues on circuit assemblies.

On this episode, Mike Konrad speaks with Mark Goodwin, COO of Ventec Europe, a supplier of copper-clad laminates and prepreg bonding materials for the circuit board fabrication industry, about supply chain challenges.

The Printed Circuit Board Association of America, or 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. My guest today is David Schild, executive director of the PCBAA. We discuss government investment in printed circuit board manufacturing in the US, the just announced allocation for PCBs as part of the Defense Production Act, and how innovation can't stop at design. This episode of PCB Chat is sponsored by PCB East, the Electronics Industry’s East Coast Conference and Trade Show. Coming to the Boston suburbs May 9-12, and registration is now open at pcbeast.com.

VVDN Technologies is perhaps best known as a provider of end-to-end engineering and manufacturing of hardware, mechanical and electronic assemblies, and embedded software, among others. Founded in 2007, it now has 11 product engineering centers worldwide, plus seven manufacturing plants across India where its capabilities include SMT, injection molding, tooling, die casting, and metal stamping, among others. The company in February announced plans to invest $100 million over the next five years in a new 100-acre factory in Tamil Nadu. That plant will add PCB fabrication capability, rounding out the firm's vertical integration strategy. Vivek Bansal, co-founder and president of engineering, discusses the company's plans and future expansion in India and elsewhere with PCB Chat host Mike Buetow. This episode of PCB Chat is sponsored by PCB East, the Electronics Industry’s East Coast Conference and Trade Show. Coming to the Boston suburbs May 9-12, and registration is now open at pcbeast.com.

Metallic Resources is a developer of high purity solder for electronics applications, making paste, bar, and cored wire products, among others. Metallic Resources’ slogan is “not your typical solder,” and one big reason for that is the high purity solder it supplies. This is credited to the company’s electrolytic refining process. David Bao, Ph,D., director of New Product Development, Erik Ozan, senior manager and head of the recycling division, and Jeff Giles sales manager of Metallic Resources talk about that refining, reclaiming, the pros and cons of risk aversion, and why some companies are wasting money stuck in higher cost solder assembly processes with PCB Chat host Mike Buetow. This episode of PCB Chat is sponsored by PCB East, the Electronics Industry’s East Coast Conference and Trade Show. Coming to the Boston suburbs May 9-12, and registration is now open at pcbeast.com.

You don't have to be in the tech industry you understand importance and value of data. Industries have always collected various sets of data, first manually and, in modern times, automatically. The volume of data has historically been limited to the ability to capture and store it. Recent advances in technology have vastly increased the ability to capture and store data. The industry 4.0 movement has fueled both of desire and requirement to capture data. We have created a "be careful what you ask for" scenario as we now are capturing data at an unprecedented rate but frequently lack the ability to discern and analyze all of our newly captured data. Luisa Herrmann, head of product for Arch Systems, is helping to transform "big data" into useful data. Luisa has 10 years of experience in product management and product marketing, launching products, building teams, and scaling organizations in the data software space. She was most recently the head of product at Cape Privacy, an encrypted machine learning company, and before that she was the Head of Product at expert.ai, an NLP company. She has a degree in chemical engineering from the University of Pennsylvania and lives in the Boston area. Luisa Herrmann may be contacted here: [email protected] https://archsys.io/

APCT in February completed the acquisition of Advanced Circuits, a printed circuit board fabricator located in Aurora, Colorado. The acquisition nearly doubles APCT’s annual revenue, to $200 million, which immediately thrust it to the number 2 spot among PCB fabricators in North America, behind TTM. Steve Robinson, president and CEO of APCT, discusses the acquisition, the pending integration, and APCT's new responsibilities as one of the largest North American PCB fabricators with Mike Buetow. This episode of PCB Chat is sponsored by PCB East, the Electronics Industry’s East Coast Conference and Trade Show. Coming to the Boston suburbs May 9-12, and registration is now open at pcbeast.com.

On this show, we’ve discussed many aspects of the electronics assembly process. We talked about reflow, thermal management, printing, soldering materials, additives, and so much more. What do all these topics have in common? When done correctly, they all contribute to the reliability of circuit assemblies. Today, we’re going to dive into the subject of cleaning circuit assemblies after reflow. For many assemblers, the cleaning process was replaced by the use of no clean flux technology. Time and technology have eroded the concept of allowing all residues to remain on the assembly. Today, residue caused failures are such a concern, that IPC recently and radically changed the way circuit assemblies are considered to be clean. Mike Konrad's guests are Sal Sparacino and Eric Camden. Sal is sirector of sales at Zestron Americas, located in Manassas, VA. Zestron is a manufacturer of cleaning chemicals for the electronics industry. Eric is lead investigator for Foresite, an analytical laboratory based in Kokomo IN. Eric, is the person you call when things go wrong. Together with my experience as a cleaning equipment manufacturer, we’ll discuss how cleaning contributes to increased reliability, and we’ll review the reasons cleaning has returned as a mainstream assembly process.

We are all aware of the “oldest profession in the world.” Perhaps the second-oldest is counterfeiting. Whenever a product is introduced, a counterfeit version soon follows. While the electronics industry has experienced counterfeit components from its inception, recent events such as the pandemic and supply chain shortages have fueled the counterfeit industry. Statistics by the Semiconductor Industry Association (SIA) reveal that the counterfeiting of electronic parts in the US alone cost the chip industry more than $7.5 billion in revenue annually. According to new data from the ERAI, a global information board for counterfeiting, reports of counterfeit electronic products are growing. Although it is difficult to put an exact figure on just how many counterfeit products are in circulation, estimates suggest that consumer and industrial businesses lose approximately $250 billion each year due to counterfeit parts. To talk more about counterfeit components and detection technologies is Dr. Eyal Weiss, Founder and CTO of Cybord. Dr. Weiss received his Ph.D. in electronic and computer engineering from BGU (Ben-Gurion University) in Israel as well as a master's in plasma physics and bachelor's (cum laude) in mechanical engineering from the Technion–Israel Institute of Technology. He worked as a researcher on pulsed plasma at Soreq Research Center (SNRC). He then worked as a technology department manager in the high-tech fiber-optics industry. He was the technology manager at Lynx Photonics and then at Explay, developing state-of-the-art silicon and optical chips production, packaging, and assembly production lines. He developed a new fiber-pigtailing and packaging technology and built full-scale production lines utilizing this new technology. He returned to Soreq SNRC and for 15 years served as manager and leading scientist of the R&D Systems Department. He built mass-production lines and assembly lines for new sensors technology and developed their test equipment. He has twice received the prestigious Israel Defense Prize. In 2018, he founded and became CTO of Cybord, developing electronic component qualification and authentication technologies. He is a member of the Israel Innovation Authority, Euramet, SAE, and IPC committees. He specializes in multidisciplinary technology development and has received significant awards and accolades in the fields of machine learning, plasma physics, optical assemblies, laser technology, and electromagnetics. Dr. Weiss is an expert in technology development and manufacturing technology and has published over 20 peer-reviewed articles, 4 patents, and a book. This podcast is brought to you by PCB East, the original conference for the #electronics #design, #manufacturing and #assembly industry on the East Coast. Coming to Boxborough, MA, on May 9-12, with the one-day exhibition and a day's worth of free technical sessions on May 10. Visit pcbeast.com for details.

This episode was recorded live at the SMTA Pan Pacific Microelectronics Symposium in Hawaii. David Raby is president of Madison Alabama-based STI Electronics, a contract manufacturer for the EMS industry. David worked at the family business since he was a child and eventually took over the family business when his father (and company founder) Jim Raby retired. The electronics industry moves at the speed of light and any business within the EMS industry must learn to stay ahead of technology and trends. David shares some of his experiences in taking over the family business and some of the challenges his business (and many other businesses) face on a near daily basis. This podcast is brought to you by PCB East, the original conference for the #electronics #design, #manufacturing and #assembly industry on the East Coast. Coming to Boxborough, MA, on May 9-12, with the one-day exhibition and a day's worth of free technical sessions on May 10. Visit pcbeast.com for details.

On this episode of PCB Chat we discuss the third quarter 2022 printed circuit design software market data from the ESD Alliance, which were released Jan. 23, 2023. Our guests are Wally Rhines, who spent more than 45 years in in semiconductor and PCB design as an executive with Mentor Graphics and before that, TI; and Merlyn Brunken, whose is the longtime market intelligence director with Siemens Digital Industries, formerly Mentor. This podcast is brought to you by PCB East, the original conference for the #electronics #design, #manufacturing and #assembly industry on the East Coast. Coming to Boxborough, MA, on May 9-12, with the one-day exhibition and a day's worth of free technical sessions on May 10. Visit pcbeast.com for details.

Travis Kelly, president and chief executive of Isola and chairman of the Printed Circuit Board Association of America, joins PCB Chat host Mike Buetow to discuss the latest policy plans in support of the US printed circuit industry, and the new president of the trade group. Kelly gives updates on HR 7677, the bill introduced last year in support of the US PCB industry, and weighs the impact of the Chips Act on similar legislation for circuit boards.

Electricity is the life blood for all circuit assemblies. It can also afflict significant damage via electrostatic discharge. Today, Christopher Almeras of Raytheon reviews the various ESD mitigation strategies as well as some ESD horror stories! Almeras began his career in process engineering for a small electronics manufacturer in the late 1990s. There he became responsible for the sites ESD compliance verification. His next career move took him to a high-volume manufacturer where he added ESD Coordinator to his process duties. He eventually made the jump into the Military/Aerospace side of electronics manufacturing (with Raytheon) in 2010 where he has remained working in process, capital installations, continuous improvement, and ESD. In 2009, he completed the ESD Certified Program Manager from the ESDA. He serves as a member on several ESD Association standards committees including S20.20, TR53, Process Assessment, High Reliability, Electrostatic Attraction among others. In 2022 he took over the working group chair for Soldering/Desoldering Hand Tools. Almeras was elected to the ESD Association Board of Directors and continues to be active with the ESD Symposium each year. In 2018 he presented his technical paper “An ESD Case Study of Defect Analysis in High Speed Electronics Manufacturing” at the symposium. Almeras has a BS in mechanical engineering from Purdue University and an MS in industrial engineering from Oklahoma State University. He is an ESD Certified Program Manager (ESDA). During this episode, host Mike Konrad references the following: Reliability Matters Episode 104: A Conversation about ESD Flooring with Thomas Ricciardelli 4 Easy Ways to BLOW UP Your Test Gear Daniel Bogdanoff - Keysighthttps://www.youtube.com/watch?v=dDvue5whx0s

Historically, circuit assemblies are rigid devices. IoT (Internet of Things) has opened up the opportunity to embed electronics into a near limitless array of form factors. Some of these form factors require the electronic assembly to be flexible such as in wearable and medical applications. To complicate matters, the metal conductors on the assembly are rigid, not flexible or malleable. That may change with the adoption of liquid metals. We were exposed to the concept of liquid metal in the 1991 film "Terminator 2." Will science fiction become reality? Mike Konrad's guest is Dr. Michael Dickey. Michael is currently the Camille and Henry Dreyfus Professor in the Department of Chemical & Biomolecular Engineering at NC State University. Michael Dickey received a bachelor's in chemical engineering from Georgia Institute of Technology and a Ph.D. from the University of Texas. From 2006-2008 he was a post-doctoral fellow in the lab of Professor George Whitesides at Harvard University. Michael completed a sabbatical at Microsoft in 2016. Michael’s research interests include soft matter (liquid metals, gels and polymers) for soft and stretchable devices (electronics, energy harvesters, textiles, and soft robotics), and hopefully, for the sake of humanity, not liquid metal T1000 villains. Dr. Michael Dickey's contact information: [email protected]

Industry 4.0, the fourth industrial revolution. Beyond the buzzwords, what does this mean? David Graham is chief technology officer of 4IR.UK, a wholly owned subsidiary of Internet of Things-focused British Systems. 4IR.UK specializes in creating monitoring, control and automation solutions, often based on the MultiPlug Edge Computing Platform, for manufacturing environments. They also provide consultancy and development for other Industry 4.0 platforms. Host Mike Konrad was intrigued by a webinar presented by David titled “A Decade of Industry 4.0 – What it Wasn’t, What it Was,” and they speak about his thoughts, experiences, and opinions of Industry 4.0.

Allspice has developed a software platform that supports users of CAD tools for collaboration, design and schematic reviews and commenting, and tracking various hardware-specific attributes such as order status, manufacturing, and connection to the PLM. Allspice CEO Valentina Ratner and CTO Kyle Dumont have extensive experience in electronics hardware and software, both with startups and some of the largest companies in the industry. They share the origins of the company, and how their personal experience drove development of the AllSpice platform, which seeks to wean the supply chain off PDFs as a product development tool.

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 the latest programs, including ones on Pb-free manufacturing, with PCB Chat's Mike Buetow.

SMTA is well known for producing high-quality relevant technical conferences and symposiums. This includes, among others, the technical conference held at SMTAI, the High Reliability Cleaning and Coating Conference, the Symposium on Counterfeit Parts and Materials, the Advanced Electronics Assembly Conference, the Wafer-Level Packaging Symposium, the Electronics in Harsh Environments conference, and the Pan Pacific Microelectronics Symposium, often referred to as Pan Pac. Pan Pac is unique in many ways, beginning with its venue. Pan Pac is held annually at one of the Hawaian islands. This fact alone makes this symposium stand out. But there are many other factors that make this symposium unique. As Pan Pac’s steering committee says: "The Pan Pacific Microelectronics Symposium strives to build bridges and nurture relationships across all boundaries, oceans and cultures, industries and technologies, companies and individuals. Its location in Hawaii always provides the requisite isolation from day-to-day distractions necessary to support these goals and enhance personal face to face interactions. The Pan Pacific continues its mission of building the vision and future directions for the electronics industry!" Pan Pac 2023 is scheduled for January 30 - February 2, 2023, at the Sheraton Kauai Resort on the island of Kauai. To talk more about the upcoming Pan Pacific Symposium, Mike Konrad invited two colleagues who are instrumental in curating the technical contact for this symposium. Dr. Chuck Bauer, one of the creators of this symposium, and Keith Bryant join him to discuss the conferences technical tracks and presentations as well as their view on what makes this conference unique.

Like most manufacturers, the electronics manufacturing industry relies on countless suppliers to fulfill its manufacturing needs. I'm quite certain there is no one within the EMS space who fabricates their own boards using materials produced in house, operates their own semiconductor foundries, designs and manufacturers their own components, and produces soldering materials for their reflow process. Our industry relies on a vast network of manufacturers throughout the world to build even the simplest electronic assembly. Intellectual property security, cybersecurity, national security, are all hot topics today. No one wants their hard-earned intellectual property stolen. This is most true within the US military establishment. There are, at present, numerous policies, procedures, and regulations designed to protect various parts of our supply chain from unscrupulous people and companies. Today, companies are concerned about “controlled unclassified information” (CUI) and “controlled technical information” (CTI). That brings us to IPC-1791. What is IPC-1791? Randy Cherry, Mike Konrad's guest on this episode, explains. Randy Cherry has over 30 years' experience in engineering and is a certified SMT process engineer and an IPC auditor. He is director of Validation Services at IPC. Validation Services is a series of certification programs that qualify products and processes to the IPC industry standards.

It's been said on this show that one key factor to international competitiveness is automation. While labor rates vary widely across the world, automation helps to level the field. Michael McHale is CEO of Production Systems Automation, otherwise known as PSA. He graduated from Drexel University with a BS degree in mechanical engineering. PSA is a privately owned engineering and custom manufacturing firm founded in 1985, with three locations in Pennsylvania. They are experienced as a turnkey systems integrator, providing solutions for capital projects including, but not limited to; flexible robotic solutions, custom automated machinery, drives and controls & custom PLC projects. They also offer a line of standard products developed for industry specific customers. They are a robotic systems integrator at heart, representing leading global robotic OEMs. He joins Mike Konrad on Reliability Matters.

Last July, Indium Corporation announced a partnership with SAFI-Tech, an Iowa-based startup that is creating no-heat and low-heat solder and metallic joining products. They call these supercooled molten metal products, and they have direct application to electronics soldering. Dr. Ian Tevis, SAFI-Tech’s president and co-founder, and Dr. Andy Mackie of Indium Corporation, discuss this supercooling platform and what’s next toward bringing it to market with PCEA president Mike Buetow.

Today we’re diving into conformal coating best practices. With the explosion of IoT, the electrification of vehicles, and the miniaturization of circuit assemblies and associated components, many of which are operating in harsh environments, the need for conformal coating has never been greater. Coating your assemblies? Where does one start? What material should one choose? Should it be applied in-house or through a contract-coating house? What are the best practices in materials selection, application, inspection, and thickness? So many questions! To answer these and other questions, Mike Konrad invited a conformal coating expert to shed light on this subject. David Greenman began his career in the conformal coating business at Concoat distributing Humiseal products and eventually manufacturing them under license for Europe, the Middle East, India and Africa. After 25 years of distributing and manufacturing Humiseal products, Chase Corp, which owns Humiseal purchased Concoat. David now serves as director of Humiseal UK, Europe and India, responsible for corporate responsibility as well as supporting HumiSeal sales and technical teams. He is qualified as a radio, TV/electronics engineer and a member of The Society of Radio and Electronics Technicians, now the Institution of Engineering and Technology.

Wang Lu is cofounder of Jove Enterprises, a China-based printed circuit fabricator with five facilities in mainland China and one pending in Thailand. She discusses the company's technical strengths and markets, and reasons for branding out to Thailand, with PCEA president Mike Buetow.

Modern electronics assembly has seen so many changes over the years. In today’s era of IoT, the electrification of vehicles, the explosion in the use of bottom terminated components, the increasing implementation of electronics into harsh environments have all contributed to the increasing complexity and difficulty of building electronics. While so much has changed, there are some things that have remained the same. One such thing is the need for ESD control. There always was and continues to be the challenge of protecting components from the dangers of static electricity. My guest today is Thomas Ricciardelli, founder and CEO of SelecTech, a manufacturer of ESD flooring for the electronics assembly industry. Tom is also the chairman of the Flooring Committee of the EOS/ESD Association. Tom earned a master's in chemical engineering from MIT and an MBA from the MIT Sloan School of Management.

Stephen Chavez spent the past 12 years as a principal engineer and global subject matter expert of PCB design for Collins Aerospace and Raytheon. This year, he joined Siemens as a senior product marketing manager, where he focuses on methodologies for adopting a strategy for resilience and integrating the Design-to-Source Intelligence insights from Supplyframe. He speaks with PCEA president Mike Buetow about automation in design, from autorouting to integrating component data in a timely fashion, to reduce design time.

Today, Mike Konrad talks about low-volume electronic assembly. We all know who the “big players” are when it comes to solder paste printers, pick-and-place machines, reflow ovens and other assembly equipment. But what choices does one have if they need to produce low volumes of electronic assemblies such as prototypes and other low-volume applications? Let’s face it, most assemblers can’t justify a multi-million-dollar production line for low-volume production. One solution may be to outsource the production to a contract manufacturer but there are specific circumstances which may prevent that. In today’s episode, we’ll review some of the equipment options for low-volume SMT production and we’ll see if the barrier to entry for in-house assembly is lower than one might think. Mike's guest today is Ed Stone. Ed is a sales manager at Manncorp, a provider of SMT assembly equipment for the EMS industry. Manncorp was founded 55 years ago back in 1967. Just imagine how much our industry has changed over the past 55 years!

Today, we're going to talk about contract manufacturing. Do you have a circuit assembly that needs to be built? Don’t have the equipment in-house or enough bandwidth or specialized expertise to build it? You may be best served by utilizing the services of a contract manufacturer. Contract manufacturers come in all shapes, sizes and capabilities. Should I seek out a Tier 1 manufacturer? How about Tier 2, 3, 4? What does tier stand for anyway? should I have my assemblies built overseas or in-country? What about issues such as ITAR? Who will be providing the components? What if I need more than just boards assembled such as design, testing and box build? To answer these and so many more questions Mike Konrad turns to his friend and colleague David Raby. David is the President of STI electronics, founded in 1982 by David's father the late Jim Raby. Those of you who have been around the electronics industry for some time will know Jim Raby for his work with the US Navy in establishing military standards for electronics manufacturing and the development of the NASA and Department of Defense Soldering Schools. Over the past 40 years, STI Electronics has expanded its focus from consulting and technical seminars to providing training, laboratory analysis, advanced research and development, microelectronics assembly, prototyping, and small to medium volume PCB contract assembly for the electronics industry. David graduated from Auburn University with a bachelor’s degree in Aviation Management.