The question not asked may be cause for concern.

It is essential for PCB fabricators to ask their customers engineering questions before production. Clarifying design requirements and expectations ensures they are fully understood, preventing costly errors, avoiding liberties being taken in the fabrication process, resulting in a product that meets both performance and reliability standards.

I write this not only to set clear expectations for customers but to strongly caution that when questions are not asked, there may be cause for concern. Questions must be asked so we can align objectives. The PCB is custom manufactured, and in many cases, the fabricator is either replicating something another manufacturer has built or creating something entirely new. In both scenarios, setting clear expectations is critical. If someone else has built it, we must know what we’re matching. Conversely, if the part number is a first-time build, the customers must understand that we’re doing something that has not been achieved.

When we ask customers questions, we are often met with resistance: “Why are you asking this? Manufacturer ABC has built the board, but they didn’t ask us for any of this. Why do you need to know?”

Previous manufacturers may not have been asked questions, instead choosing to make determinations about the design intent on their own. They made an assumption and ran with it – often, this crucial step was skipped for the sake of speed, because they didn’t know any better or they had a capability that isn’t widely manufactured at other factories.

We ask these questions to understand the design and set clear expectations, ensuring the boards we build meet the mark every time without any risk or shadow of doubt.

We’re often held up against other North American fabricators. North America is predominantly a quickturn industry, with high-mix, low-volume board shops operating on a 14-day turn or under. Customers pay a premium for that, sometimes 10X the prices in Asia. That premium is usually for speed. And how do you do things faster? You don’t ask: you just do.

That is a conflict with the type of manufacturing we do offshore, which is mostly slightly longer term and larger volumes. Even when we are at those speeds, we are geared for high demand, high-quality builds. Our teams lead with questions to ensure quality is built into the board.

If the PCB has been manufactured previously and answers to the engineering questions (EQs) are unknown without working files, we can take the board, cross-section it, grind and scan it and see what was done. For example, in a recent case with a customer, we found the board actually matched the EQ we were asking – which did not match the customer’s procurement data. We were able to show the customer: “This is what I’m asking you. It’s exactly what you were getting before – you just didn’t know it.” This specific customer is now sending us multiple part numbers for microsectioning so we can confirm what they’ve been receiving and match it, regardless of what their data says.

The difference could be a variety of things. It could be equivalent material or dielectric usage. The customer could specify 4 mil dielectric while the previous supplier used 2 mils. The customer may never have noticed, but we can show it on a microsection. Copper weights as well; the customer could have asked for 2oz. copper but the supplier gave them 1oz. with Class 3 plating, which IPC standards permit. Both scenarios can have a profound impact on the current carrying capability of the circuitry.

When the customer takes time to understand this, their reactions are usually favorable. It helps them understand why we ask questions and shows the value added. Sometimes, honesty can be a detriment: Quickturn-centric customers are so focused on speed, they don’t focus on quality. When we show them, this is why we’re asking, they realize if their specifications were clean, we could have been as quick as their other suppliers.

There have been cases where customers insist on their original specification even when we show them discrepancies. Some customers will say, “We want 2oz. copper,” or “We want 70µm minimum.” Even if the design doesn’t support it, they remain adamant. Some have canceled orders and gone elsewhere. (Whether they received what they specified or were given something different without knowing is another matter.)

The EQ exchange is how integration with customers should be done. EQs are how we bridge the gap with the customer’s purchasing and engineering teams. This dialogue allows us to collaborate and ensure reliability.

Sometimes, the questions seem minor, like solder mask coverage over vias. If one side is covered and the other is open, it’s like a cup holding residual chemistry. We ask: Do you really want this, or can we add clearance so the via drains? Customers don’t always understand at first, but upon hearing the explanation they realize it’s a reliability risk. The ones who are receptive incorporate the feedback, improving designs that save them money in the long run.

Engineering questions are not just a formality, they are a critical safeguard against assumptions that can lead to compromised quality and performance. While some customers may resist these inquiries, the reality is that asking the right questions ensures clarity, reliability and consistency, especially in an industry where expectations vary, designs evolve and previously utilized manufacturing practices may not always align with specifications.

In the end, these conversations strengthen partnerships, improve designs and reinforce the value of transparency in PCB fabrication.

Jeffrey Beauchamp is director of technology & engineering at NCAB Group USA (ncabgroup.com); This email address is being protected from spambots. You need JavaScript enabled to view it.. He started his career in the PCB industry in 2003 at PD Circuit, now part of NCAB Group, and works with PCB customers to provide optimal solutions.