Consumer PCB Assembly Design Mistakes that You Should AvoidPosted on 2020-06-22
Mistakes to Avoid when Submitting Consumer PCB Assembly Design
Printed Circuit Boards hold great importance in the consumer appliance industry. They have the ability to make to break the appliance. Statistics show that around 94% of the consumer PCB assembly data submitted is prone to errors.
This would lead to errors in the prototypes. After all, the Printed Circuit Board assembly houses extract design from this data and then create PDF images as well as design files. To reduce error probability, on average, manufacturers create 11.6 physical prototypes for less complicated Printed Circuit Boards.
However, for more complex and sophisticated Printed Circuit Boards, the number of prototypes goes up to as many as 16. In addition to causing you extra money, these prototypes are also time-consuming. It is something that you would want to avoid especially if you have a deadline to meet.
So, what are you to do? Simple, ensure that you do not make the following mistakes while submitting PCB design for consumer appliance.
Common Mistakes in Consumer PCB assembly Design
You should be avoiding mistakes in your own PCB design, but at the same time, you should also partner with reliable PCB manufacturers such as the 6pcba. A good and experienced PCB manufacturer has engineers who would review your design in detail. They would pinpoint the errors and make the required corrections.
Of course, they not going to changing the functionality. On the contrary, they would make the design workable. You must be thinking that if there are people who catch mistakes, why bother with them in the first place?
For starters, a design with errors requires additional time for prototyping. After all, the engineers would have to find mistakes and then make corrections. Send it to you for approval and repeat it.
Further delays can be caused in case the PCB assembler is unable to find a correction for an error while looking into other project files.
Also, when a PCB manufacturer is going to make changes to the design, there is a probability that it might affect its functionality. Something you would not want. After all, you did design the PCB while keeping in mind the need for your product.
Therefore, we recommend that to make the design as error-free as possible.
Corrupt or Missing Files
When you send your design file to the assembly manufacturer, double-check it. You will be surprised to know that assemblers come across numerous corrupt or missing files. For instance, the Gerber files including the paste mask layer, or stencil are missing or corrupt.
Likewise, the XYRS data file is missing. In some cases, the lack of a Bill of Materials can lead to additional delays. All these files hold great importance for the PCB fabrications. Therefore, you cannot ignore these files. Below, are the functionalities of every file.
Gerber files come with. GBR format. These files describe the layers of Printed Circuit boards. For instance, the copper layers – ground plates and the traces—drilling holes details, solder masks, board outline, inner layer information among others. Since all this plays a vital role in PCB design, Thus, you need to incorporate the file right.
For the correct placement of PCB’s components, you need to have the right XYRS file intact. The file provides information regarding components on the X-Y axis. In addition, it will indicate the component rotation, side on which the components are to be placed, and the type of components.
For example, the Through-hole component placement or the Surface Mount placement. In addition, .XYRS extension files contain info regarding part footprint, etc.
It is a list that holds data the basic data such as the part number, reference name, component quantity, and the manufacturer info. The list does not have information about the location. It is important to pay extra care to the BOM file.
The reason being, designers and engineers often complete this file in limited time. Believing it to be less important they are not careful, thus resulting in a number of errors. In addition, overlooking is multiple times make your brain believe that it does not have any error.
So, a good way to ensure an error-free BOM file, it to look it with a fresh mind. Let’s say, the first thing in the morning you would do. Also, the correct reference designators would eliminate the ambiguity associated with component placement.
Ensure that all the design files are in the correct format, and contain all the required data.
Polarity Markings on your Consumer PCB Assembly File
Correct Polarity marking is another important aspect of the Consumer PCB assembly design. Incorporating incorrect markings can lead to a number of issues. Component stuffing being on the top.
For instance, if you are designing a diode, it is important for you to mark both the anode and the cathode correctly. Use a “Plus Sign” to indicate the polarized capacitor in the correct place on the Printed Circuit Board.
In the case of an Integrated Chip, you need to identify Pin one. Mark it on the correct location on the board. To add virtual parts, you need to incorporate Circuit Simulators. Therefore, ensure that the final Printed Circuit Board Design Files incorporate or excludes them as per your PCB design.
Sub-optimal sizes seem to be a subtle problem for the land patterns. Despite interchanging both terms “landing patterns” and “footprints”, they are different. This difference has a great impact on manufacturing quality.
Informally known as the real estate, a footprint is component’s imprint of the area that you cover on a Printed Circuit Board. Think of it as you would of soft dirt in which you would press the components.
Land Pattern, on the contrary, refers to the size as well as the outline of the pad, then you would need for the Printed Circuit Board components. There is a difference in size as well. The footprint is generally smaller in comparison to the land pattern.
After all, the land pattern is going contains information regarding the PCB pads, its component lead landing, and soldering. Often, designers use component datasheets for land patterns. Just make sure that the land patterns match the component footprint.
Using the right land patterns have the ability to enhance the overall quality of manufacturing.
Length and Height Missing Notes
Not specifying the height and the length on the drawing might result in a bigger size of the Printed Circuit Board. It might just not fit into the enclosure that you are designing it for. After all, the height and thickness of the Printed Circuit Board are going to have a direct impact on your ability to fit into to required component.
This would get more difficult, once you stuff the components on the PCB. In case, your project is size limited, then we suggest your design incorporates taller components. As the height would not be a big concern.
NOTE: There is a difference in cost between the standard and the customized Printed Circuit Board.
Special Instructions for your Consumer PCB Assembly Design File
A PCB assembler does not have the magic to read your mind. Therefore, you need to specify each and everything to offer clarity. For this purpose, choose a readme.text file. Incorporate all the additional information and instructions in it.
Doing so, you are will help the PCB assembler to interpret error-free PCB. Thus, provide 3D drawings, Schematics, notes, and other specific features. You can even tell them how you plan to use the Printed Circuit Board. Doing so will further enhance clarity.
If you meticulously review your PCB layout and with other PCB files, you are actually reducing the chances of error to a great extent. It would make a mark difference during the debugging of your prototype.
After all, simple mistakes can result in hours if not days of troubleshooting. Something, you would want to avoid especially when your project is time-restricted. So, after reviewing them thoroughly, bundle all your files in a.Zip or.RAR format.
This would ensure that the assembler gets all the information in one go. Sending multiple emails consisting of different files would not only cause delays, but it would also lead to mistakes at the assembler’s end.
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