
PCB Prototyping Pitfalls: 5 Must-Check Details for Engineers to Avoid Wasting Time and Money
2025-09-22
1. Introduction: Have You Experienced the Pain of Prototyping Failures?
Many engineers spend a week on PCB design, only to have the prototype fail due to a small oversight during prototyping—like forgetting to mark silkscreen direction (causing reversed component soldering) or choosing the wrong board material (resulting in insufficient high-temperature resistance). PCB prototyping costs little, but repeated rework seriously delays project progress. Today, we’ll share 5 details to check before prototyping.
2. 5 Details to Check Before Prototyping
Detail 1: Silkscreen "Clear and Non-Overlapping" to Avoid Soldering Errors
Silkscreen guides soldering. Blurry, overlapping silkscreen or incorrect polarity markings (for diodes, capacitors) cause reversed component soldering and direct board failure.
Check Method: Enable the "3D View" in design software (e.g., Altium) to see if silkscreen covers pads or overlaps with other components. Focus on checking "±" or "PIN1" markings for polar components to ensure clarity.
Detail 2: Board Material "Matches Application Scenarios"—Don’t Blindly Choose Expensive Ones
Different scenarios require different PCB materials. For example, FR-4 works for ordinary consumer electronics, while FR-4 high-Tg (Tg ≥170℃) is needed for industrial high-temperature environments (temperature >85℃), and PTFE high-frequency materials for high-frequency communications (e.g., 5G). Choosing the wrong material causes PCB deformation or performance degradation in use.
Selection Advice: Use FR-4 (Tg 130-150℃) for general projects, FR-4 high-Tg (Tg ≥170℃) for industrial projects, and PTFE or Rogers materials for high-frequency projects. Clearly note the material model and parameters in the prototype order to avoid wrong deliveries.
Detail 3: Copper Thickness "Meets Current Requirements" to Avoid Board Burning
Copper thickness determines the PCB’s current-carrying capacity. Too-thin copper causes copper foil overheating and burning when high current passes through. For example, 1A current requires at least 1oz (35μm) copper, and 2A requires 2oz (70μm). Many beginners default to 1oz copper, ignoring current needs.
Calculation Method: Use the formula "Current Capacity (A) = Copper Thickness (oz) × Trace Width (mm) × 0.8". For example, a 1oz copper trace with 2mm width has a current capacity of ~1.6A. If current exceeds 2A, switch to 2oz copper or widen the trace.
Detail 4: Hole Size "Matches Component Pins" to Avoid Insertion Issues
Too-small through-holes or pin holes prevent component insertion; too-large holes cause cold soldering. For example, for a component with 0.8mm pins, the pin hole diameter should be ~1.0mm, and the through-hole diameter ~0.6mm (with a 1.2mm pad diameter).
Check Method: Refer to the component datasheet in the design software to confirm pin diameter. Make pin holes 0.2-0.3mm larger than the pin diameter, and through-holes 0.1-0.2mm larger. Avoid holes smaller than 0.3mm (difficult for manufacturers to process, prone to drill breakage).
Detail 5: "Panelized Design" Reserves "Process Edges" for Easy Production
Omitting process edges for panelized prototyping (multiple small PCBs combined) makes machine soldering impossible—only manual soldering is feasible, which is inefficient and error-prone.
Design Requirement: Reserve 5-10mm process edges around the panel. Add positioning holes (3mm diameter, no copper) on the edges for machine alignment. Connect PCBs in the panel with "V-CUT" or "mouse-bite holes" for easy separation later.
3. Conclusion: The "Final Step" Before Prototyping—Confirm with the Manufacturer
Before prototyping, send Gerber files to the manufacturer and ask their engineers to check for design issues (e.g., whether hole size, copper thickness, and material meet processing capabilities). Many manufacturers offer free DFM (Design for Manufacturability) checks, which effectively avoid rework. Remember: Spending 10 minutes checking before prototyping is better than 10 days of rework later.
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PCB Anti-Interference Design: From Theory to Practice, 3 Key Tips for Stable Signals
2025-09-22
1. Introduction: Why Does Your PCB Suffer From Interference?
When designing industrial control or high-frequency circuits, many engineers face this problem: the PCB works normally in the lab but experiences signal loss or data errors on-site. This is mostly due to inadequate "anti-interference design." Interference comes from sources like electromagnetic radiation, poor grounding, and power noise, but solutions follow a clear pattern. Today, we’ll share 3 practical anti-interference tips you can apply directly.
2. 3 Practical Anti-Interference Tips
Tip 1: "Single-Point Grounding" vs. "Multi-Point Grounding"—Choose the Right One
Grounding is the foundation of anti-interference, but many people confuse the application scenarios of these two methods. For example, using single-point grounding for high-frequency circuits (frequency >10MHz) leads to overly long ground wires, creating parasitic inductance that introduces interference. Using multi-point grounding for low-frequency circuits (frequency
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China Launches Anti-Dumping Investigation into U.S. Chips
2025-09-19
September 15 News – Recently, China’s Ministry of Commerce has initiated an anti-discrimination investigation into U.S. chip trade policies and a separate inquiry into dumping practices.
The first investigation will examine whether Washington has discriminated against Chinese companies in its chip trade policies. The second will focus on alleged dumping of certain U.S. analog chips used in devices such as hearing aids, Wi-Fi routers, and temperature sensors.
In a statement, the ministry noted that in recent years, the U.S. has imposed a series of restrictions on China regarding chips, including trade discrimination investigations and export controls.
It added that such "protectionist" practices are alleged to discriminate against China and aim to curb and suppress the development of high-tech industries in China, such as advanced computing chips and artificial intelligence.
A spokesperson for the Ministry of Commerce stated in response to media inquiries that the anti-dumping investigation was initiated upon the application of China’s domestic industry and complies with Chinese laws, regulations, and WTO rules. The investigation involves general-purpose interface and gate driver chips imported from the U.S.
The spokesperson mentioned that preliminary evidence submitted by the applicant shows that from 2022 to 2024, the volume of the investigated products imported from the U.S. increased by 37%, while the import price decreased by 52%. This has suppressed and driven down domestic product prices, causing harm to the production and operations of the domestic industry.
The spokesperson added that after receiving the application, the investigating authority reviewed it in accordance with the law and determined that it met the conditions for initiating an anti-dumping investigation. The authority will conduct the investigation in accordance with legal procedures, fully safeguard the rights of all interested parties, and make an objective and fair ruling based on the investigation results.
The spokesperson also stated that recently, the U.S. government has broadly defined national security concepts, abused export controls and "long-arm jurisdiction," and imposed malicious blockades and suppression on China’s chip products and artificial intelligence industry. These actions seriously violate WTO rules and undermine the legitimate rights and interests of Chinese companies, to which China firmly objects.
General-purpose interface chips are integrated circuit chips designed to provide diverse interface types for connecting various devices, systems, or components to achieve efficient data transmission and signal conversion. Gate driver chips are integrated circuit chips used to enhance the output of gate control signals from controllers and manage the switching on and off of power semiconductor devices.
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Source: Guoxin Network
Disclaimer: We respect originality and value sharing. The copyrights of texts and images belong to the original authors. The purpose of reposting is to share more information, and this does not imply our endorsement of the views. If there are any infringements, please contact us, and we will delete them as soon as possible. Thank you.
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Foxconn Mobilizes Nearly 200,000 Workers for iPhone 17 Production Rush
2025-09-19
On September 10, Beijing time, Apple officially unveiled four new models: the iPhone 17, iPhone Air, iPhone 17 Pro, and iPhone 17 Pro Max, with starting prices in China set at 5,999 yuan. Among the newly launched iPhone 17 Pro series, the orange, blue, and silver color variants are manufactured at Foxconn's Zhengzhou Port Area facility.
The Zhengzhou Port Area is currently in the mass production ramp-up phase for the iPhone 17 series. As production scales up, the demand for labor continues to grow. Reports indicate that "Foxconn has recruited more workers this year compared to last year." "In August, the referral bonus peaked at 9,800 yuan. During the high-demand period, tens of thousands of workers were hired daily, with the hiring surge lasting an entire week."
Temporary workers, particularly those referred through bonus programs, form a significant part of the workforce. These "referral bonus workers" receive an additional payout upon completing a specified employment period. Combined with their regular wages, they can typically save over 20,000 yuan within three months. In addition to these workers, Foxconn also employs hourly temporary workers.
During Apple's annual fall product launch cycle, the Zhengzhou Port Area factory enters its busiest period of the year. The demand for temporary workers spikes, driving referral bonuses higher. By late June, bonuses rose from 4,800 yuan to 5,000 yuan within three days. In late July, they exceeded 8,000 yuan, reaching a peak of 9,800 yuan in August before dipping to 7,300 yuan by month-end. In early September, bonuses quickly rebounded, surpassing 9,000 yuan and returning to high levels.
On the production floor, nearly 200,000 workers operate in two shifts, handling tasks such as screw fastening, film application, and component assembly. Conveyor belts continuously transport finished iPhone 17 units to the packaging workshop, where they are placed into white boxes bearing the Apple logo.
However, this workforce size is not the facility's historical peak. "At its highest, the facility employed up to 400,000 people. Apple was even more popular back then, and Foxconn was the primary manufacturer. Now, orders are more distributed, and Foxconn is no longer the sole producer," noted a source. Staff at the port area's human resources service center also confirmed, "Recently, thousands of workers have been entering daily—the volume is immense."
A long-term Foxconn employee with over a decade of experience mentioned that these temporary workers typically have contracts lasting only two to three months, aligning with the critical production ramp-up phase for Apple's new products. After this period, once production targets are met and order demand stabilizes, the facility gradually begins scaling down production lines.
A Foxconn Group HR manager stated that since August, overtime intensity has increased significantly. "Overtime work has surged dramatically, unlike last year's pace." Future production rhythms will depend on market conditions following the new product launch.
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Source: Guoxin Network
Disclaimer: We respect originality and value sharing. The copyrights of texts and images belong to the original authors. The purpose of reposting is to share more information, which does not imply endorsement of the views. If any infringement occurs, please contact us, and we will delete the content promptly. Thank you.
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고주파 PCB 생산의 특수 공정 요구 사항
2025-08-22
TP1020과 같은 고주파 PCB는 10GHz 이상에서 작동하는 응용 분야에서 최적의 성능을 보장하기 위해 일련의 특수 제조 공정을 필요로 합니다. 표준 FR-4 기반 PCB와 달리, 이러한 고성능 기판은 전기적 무결성, 치수 안정성 및 재료 특성을 유지하기 위해 모든 생산 단계를 세심하게 관리해야 합니다.
재료 취급 및 준비
TP1020과 같은 고주파 재료의 독특한 구성—유리 섬유 강화재가 없는 세라믹 충전 폴리페닐렌 옥사이드(PPO) 수지—는 특수 취급 프로토콜을 필요로 합니다. 라미네이션 전에 원자재는 습도 수준이 30% 미만이고 온도가 23±2°C로 유지되는 제어된 환경에 보관해야 합니다. 이는 TP1020의 최대 흡수율이 0.01%임을 감안할 때 중요한 수분 흡수를 방지하며, 이는 10GHz에서 유전율 변화가 ±0.2를 초과하는 원인이 될 수 있습니다.
절단 및 트리밍 작업에는 표준 초경 블레이드 대신 다이아몬드 팁 도구가 필요합니다. TP1020에는 유리 섬유 강화재가 없기 때문에 과도한 기계적 스트레스를 받으면 칩핑이 발생하기 쉽고, 이로 인해 신호 무결성을 저하시키는 미세 균열이 발생할 수 있습니다. 레이저 절단은 비용이 더 많이 들지만, 소형화된 안테나에 사용되는 31mm x 31mm 보드에 필요한 ±0.15mm 치수 공차를 달성하는 데 선호됩니다.
라미네이션 및 코어 처리
고주파 라미네이트는 유전체 일관성을 유지하기 위해 정밀한 라미네이션 매개변수를 필요로 합니다. TP1020의 경우 라미네이션 공정은 190±5°C에서 200±10 psi의 압력으로 작동하며, 유리 섬유 강화 재료에 사용되는 300+ psi보다 훨씬 낮습니다. 이 낮은 압력은 PPO 매트릭스 내에서 세라믹 입자 변위를 방지하여 전체 보드 표면에서 목표 유전율 10.2를 유지합니다.
TP1020 PCB의 4.0mm 코어 두께는 라미네이션 시 연장된 체류 시간—일반적으로 표준 기판의 45분과 비교하여 90분—을 필요로 합니다. 이 제어된 가열 사이클은 고주파에서 신호 반사 지점으로 작용하는 내부 공극을 생성하지 않고 완전한 수지 흐름을 보장합니다. 라미네이션 후 냉각은 TP1020의 CTE가 40ppm/°C(X/Y축)인 것을 관리하는 데 중요한 열 응력을 최소화하기 위해 분당 2°C의 속도로 진행되어야 합니다.
드릴링 및 도금 기술
고주파 PCB 드릴링은 TP1020과 같은 재료의 연마성 세라믹 충전재로 인해 고유한 문제를 제시합니다. 표준 트위스트 드릴은 조기에 마모되어 5μm를 초과하는 구멍 벽 거칠기를 유발하며, 이는 고주파 신호 경로에 허용되지 않습니다. 대신, 130° 포인트 각도의 다이아몬드 코팅 드릴 비트가 0.6mm 최소 구멍 크기를
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