Defense Speak Interpreted: It’s Time for a ‘Defense-Speak’ Update
Beyond the Board: The Future of Innovation—Why the Electronics Industry Needs You
American Made Advocacy: New Congress, New Opportunities
Case Study: PCB Design Flaws Affect Product Cost
December 3, 2024 | Matt Stevenson, ASC SunstoneEstimated reading time: 1 minute
In the rapidly evolving aerospace industry, precision and reliability are paramount. “AeroTech Solutions” (not the company’s real name), an aerospace company specializing in satellite technology, recently faced a significant challenge that tested its operational integrity: A flaw identified in the PCB design of its latest satellite model led to unexpected delays and cost overruns. This article explores the issues the company encountered, its collaboration with its PCB manufacturer to resolve these challenges, and the steps taken to ensure project success moving forward. The real cost to manufacture can be greatly affected at the PCB design level.
AeroTech Solutions has built a reputation for innovation and excellence in the aerospace technology market. With numerous successful satellite projects under its belt, the company was poised to launch its newest satellite designed for advanced communications and earth monitoring. However, during the final stages of production, the engineering team detected a flaw in the PCB design which was causing functional failures and putting the satellite’s operational functionality at risk.
The Issue: PCB Design Flaw
The PCB design flaw was identified during the final test stage of the prototype PCBA. Engineers kept finding assemblies that showed the flaw at various levels throughout the testing phases, and finally identified the root cause during final test. They discovered that the designer had overlooked critical routing on a very sensitive portion of the design. That created issues with the clean transfer of the signal and created isolated overheating. This led to delamination and jeopardized the satellite’s mission objectives.
To read the entire case study, which originally published in the November 2024 PCB007 Magazine, click here.
Share on:
Suggested Items
Just Because You Can, Doesn’t Mean You Should
03/20/2025 | Tony Plemel, Flexible Circuit TechnologiesDecisions are usually made by gathering information and differing opinions, then making the best choice based upon that information. The same process is used when designing flexible circuits and rigid-flex circuits. For example, when designing a flex circuit or rigid-flex circuit, we consider some basic factors.
Calling All Designers: The Latest Design Technology and AI
03/20/2025 | Andy Shaughnessy, Design007 MagazineAdvanced design technology and AI were in the spotlight at the annual Design Town Hall, held March 19 during IPC APEX EXPO 2025. Speakers included IPC’s Peter Tranitz, Matt Kelly, Devan Iyer, as well as a panel on the use of AI in PCB design moderated by Susan Kayesar of Siemens.
Cycuity Collaborates with SiFive and BAE Systems to Demonstrate Advanced Microelectronics Design Supply Chain Security
03/20/2025 | BUSINESS WIRECycuity, a leader in hardware security solutions, has collaborated with SiFive and BAE Systems to deliver increased, evidence-based security assurance for third-party intellectual property (IP) in a cost-effective and repeatable manner.
DuPont Interconnect Materials Enabling Advancements in Aerospace & Defense, Next-Gen Automotive, and AI
03/19/2025 | DuPontDuPont Interconnect Solutions (ICS)—a leading material solutions and systems design partner within DuPont Electronics & Industrial that addresses signal integrity and power and thermal management challenges—will showcase the benefits of its materials for printed circuit board (PCB) manufacturing and electronics assembly at IPC APEX Expo.
Lockheed Martin's AN/TPQ-53 Radar Strengthens U.S. Northern Command's Mission with Cutting-Edge Open Architecture Software
03/19/2025 | Lockheed MartinLockheed Martin has successfully integrated its AN/TPQ-53 multi-mission radar (MMR) with the Joint Task Force – Southern Border (JTF-SB) command and control systems in an operational environment, supporting U.S. Northern Command's (USNORTHCOM) southern border mission.