Designer’s Notebook

John Burkhert, Jr.From test coupons and burn-in chambers to ICT and flying probes, effective factory testing is essential for delivering reliable products and maintaining process control.

Factory testing comes in numerous flavors. The goal is to ship products that work in the field. Failures erode gross margins, which in turn affect the company’s market perception. Good customer relationships depend on the timely delivery of products that meet the requirements, which is the definition of quality. IPC-TM-650, Test Methods Manual covers the test procedures in detail.

Read more: ICT vs. Flying Probe: Factory Testing of PCB Assemblies

John Burkhert, Jr.Effective PCB testing depends on balancing electrical validation with manufacturable design practices throughout product development.

“Don’t get testy with me.” People might say those words when they’re annoyed by a challenging statement. The point of testing is to challenge assumptions. It’s the “find out” phase of product development. Printed circuit boards benefit from testing at multiple stages of production. Let’s dive into the deep end.

Read more: Printed Circuit Board Design for Test

John Burkhert, Jr.Connector selection and footprint design require careful DfM consideration, as tolerances, spacing and assembly constraints directly impact manufacturability and performance.

When it comes to interconnects for printed circuit boards, I found one vendor with 25,217 options. A specialty vendor offered only about 9,000 different connector SKUs. Luckily, connector selection can typically be narrowed by pin count, pitch and other key parameters.

Read more: A Guide to PCB Connectors: Selection, Design and DfM Tips

John Burkhert, Jr.In PCB fabrication drawings, the nominal value gets the spotlight, but the tolerances decide what actually ships.

When it comes to coloring in the fabrication drawing, the way we provide the data creates the space the fabricator must fill. For each datapoint, there is a least material condition (LMC), a maximum material condition (MMC) and a nominal. Process variation is permitted between the two extremes and rejected when it is outside the envelope.

Read more: Tolerances and Dimensions for PCB Fabrication

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