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The Chemical Connection: A Few Things That Still Scare Me

The PCB fabrication industry is constantly changing and throwing new challenges our way. Initially, these changes and evolutions can be frightening, but we’ve always managed to adapt, incorporate these them into our processes, and continue on. But what do some of us find frightening in the industry environment now and in the near future?

Emerging technologies can be frightening, especially since they represent the unknown. It usually means changing how we do things and finding new (and uncomfortable) ways of operating. That could mean spending more on new equipment and processes, which can also be frightening.

This can be especially so for smaller shops that don’t have the extra budget funds for new equipment. Some emerging technologies of the past seemed to threaten the importance of PCBs or even attempt to eliminate our industry. Yet somehow there has always been the need for interconnects, and the industry has survived and even thrived.

Yes, some companies have failed. But others have embraced new technologies and grown. Such is the nature of the business. However, while there are things about new technologies to be afraid of, they also present new opportunities, and so far, this industry has successfully integrated them into its businesses. But to put things into perspective, let’s take a quick look at some of the previous “emerging” technologies that raised concerns.

New Technologies Can Be Scary
The 1950s (before my time): What? You want to put thin sheets of copper on fiberglass and form circuits by removing unwanted copper by spraying it with hot acid? Don’t you know that’s what wires are for?

The 1960s (still before my time): What? You want to put copper sheets on both sides of the panel, then drill holes through the panel and plate copper inside the holes on fiberglass and epoxy to provide an electrical interconnect between the top and bottom of the panel, so you can use both sides for circuits? Are you crazy?

The 1970s (now we’re talking): What? You want to stack these double-sided panels on top of each other to form multilayers, then line them up and laminate them together so we can drill and plate hundreds of smaller holes to electrically connect all the layers, using even less space. Are you out of your mind?

The 1980s: What? Now you not only want to use even thinner fiberglass substrates (0.002" thick) for your multilayers so you can stack even more layers in the same thickness, but you also want to use flexible substrates so you can bend them to fit into even tighter spaces? Oh, and you also want to make the circuit lines even smaller, like less than 0.005". C’mon, man, get real.

The 1990s: What? You want to put the entire circuit board on a tiny chip? Are you trying to put us out of business?

It’s now 2026, and thus far, the industry has navigated the shoals of new technologies. I don’t see this changing anytime soon. While new technologies certainly cause anxiety, they should be seen as opportunities rather than something to be feared.

Fears About AI
As I mentioned in last month’s column, I am leery of the impending AI revolution. Not so much about the implementation of AI itself—that will happen whether I like it or not. But I’m leery of the rush to use it before it’s proven to reduce the workforce.

We’ve all read about tests with autonomous AI running various businesses that have failed, usually spectacularly. I’m reminded that the learning algorithms built into them are developed by human coders who have a reputation for not living in the real world like the rest of us and for not being especially socially adept.

My feeling is that no AI should be allowed to run any process or business without human supervision. AI has no human empathy. Those of you who have tried to call a help line with an AI operator know what I mean.

Here’s a story that I think illustrates my point. Recently, I had a problem with my card from a national bank, and I had to spend at least 15 minutes finding the right wording to reach a real person on the line who could help with a problem not on the AI menu. I call these AI reps Artificial Idiots. They are especially annoying because you can’t yell at them to relieve your frustrations as you can with a natural human idiot. After all that, I ended up canceling my national bank card and going with a local bank. At least I can talk to a real person when I have a problem.

I’m all right with AI, but not AI without human supervision and oversight. I think those who try to use autonomous AI to replace skilled and entitled workers for lower pay and less skilled workers are in for trouble.

Skilled Workforce Fears
Okay, enough about my AI concerns. I am also concerned about having a skilled workforce, not so much for our company but for the industry in general. My company is fortunate to have a low employee turnover rate, so when people retire or otherwise leave, it’s not too much effort to promote from within to fill those positions. When we need to expand the workforce, we can hire entry-level candidates with confidence that they will stay long enough to become productive members of the team.

One exception is more staff for our process lab. It is difficult to find candidates willing to work with the chemistries and processes involved in our testing and development work for our equipment (and to work with the two crazy people already there). I’m sure this is not a surprise, as many of you are facing the same problem and, as a result, are increasingly turning to your suppliers for process support. Which is why we are looking for more process people.

What concerns me is that, while we have gained a lot of process experience over the years and are more than willing to share it with our customers and provide guidance and help where we can, we are an equipment manufacturer, not a process engineering service company. Being willing to help but not having the resources to help everyone who needs it is a great concern.

These are just a few of the things I find “scary” this Halloween season. I see that I am running out of column space (again), so I’ll leave it here.

This column originally appeared in the October 2026 issue of I-Connect007 Magazine.