PCB design – From electronics development to production, everything revolves around the printed circuit board

The (usually) green, copper-coated circuit board is a central component in an electronic product and the electronics industry would be unthinkable without it. Andreas Höhn, Head of PCB Design & Electronics Development Laboratory, describes the interface role of a PCB designer and highlights the central contribution that a printed circuit board makes to a successful end product.

The printed circuit board is the centrepiece of the world of electronic hardware. For it to be manufactured, a functioning PCB design is needed, which is laid out using the most modern tools. Housing space conditions, EMC interference, signal integrity, layer structure, routing, production suitability and other topics are the challenges that must be overcome.

Technical trends such as IoT with numerous interfaces and high data throughput, as well as wireless connectivity, are omnipresent in the electronics industry. With them, the demands on products have also changed dramatically in recent years.

Printed circuit boards through the ages

In the past, a PCB layout consisted of THT components, conductor tracks and a few plated-through holes, which could be created with a simple layout program. Alternatively, the layout was even taped off by hand with black adhesive tape and the PCB was exposed and etched "in the basement". The layout was only created in 2D.

PCB layout

Earlier

PCB layout

Today

PCB layout

Earlier

PCB layout

Today

PCB layout

Today

Nowadays, creating a layout is more complex in many ways, as it involves more than just placing components and drawing tracks. This is because the requirements for an electronic device have changed over time, and with them the requirements for a PCB layout and, equally, for the PCB designer in its implementation.

Motherboard with CPU, semiconductors and circuits. Microelectronics and server hardware, blue core technology in the background. Concept of an electronic device

In the field of power electronics, ever higher currents are being realised on smaller printed circuit boards.
In the field of housings, the dimensions and space available for the printed circuit board are becoming increasingly limited.
In the field of sensor technology and communication technology, signals are becoming faster and faster and/or a radio antenna is being realised directly on the printed circuit board. The layout must be created according to the teachings and knowledge of so-called "high speed design".

The variety of layouts in the specific technical areas has grown considerably, as has the variety of different possible PCB technologies. Whether it is standard FR4 or more specialised FR4, StarrFlex, Flex or even printed plastic parts with copper and assembled components, the world of PCB design is becoming more and more interesting and diverse.

Nowadays, it is also possible to display the layout in 3D in the layout program. Likewise, the components, conductor tracks, etc. can be moved directly in the 3D view and even integrated into the housing (step model). This means that any collisions between components or even with the housing can be detected at an early stage.

Expertise and interdisciplinary co-operation

Along with the requirements for a PCB layout, the role of the PCB designer has also changed – it is complex, interesting and varied. Sophisticated layout programmes, multi-layered electronic hardware and trend topics that develop rapidly require comprehensive expertise. Further training is therefore part of the core mission.

Factors for successful product development, from electronics development to the production of the printed circuit board, include close cooperation and constructive dialogue with various internal and external departments.

Click on the orange dots to get an overview of the interfaces to the individual departments.

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Electronics development

The first milestone in creating a layout is to work closely with the electronics development team. From the outset, topics such as EMC, temperature resistance, currents, placement, technology, etc. should be taken into account. The same applies to the correct choice of components and, if necessary, a procurement solution for the most important components. For sample or prototype production, the PCB designer supports the PCB assembly and procurement of components.

Housing design

The dimensions and spatial conditions of the printed circuit board in a housing require close coordination between the housing construction and the PCB designer. The eternal "chicken or the egg" discussion between the beautiful design of the housing and the inner workings of the end product should be avoided here. In most cases, the space estimation milestone helps in advance. If the housing is already specified, it can sometimes be difficult to create a functioning layout. However, a few millimetres of change in the design or a small repositioning of buttons can often solve a problem. Through continuous subject-specific exchange, precisely these problems can be solved together at the outset.

Test equipment manufacturing

A test device is needed so that the assembled circuit board can also be tested. At STEINEL, we have our own in-circuit test department and a function test department. For the construction of a test device, the cooperation between the PCB designer and the test equipment department is essential. The placement of test points, capture holes, etc. on the layout must be coordinated with the test equipment. This coordination step should be done as early as possible.

Purchasing

When it comes to PCB procurement, the PCB designer supports the purchasing department with technical aspects when selecting the PCB and PCB manufacturer, because in terms of quality, the manufacturers sometimes differ enormously. Finding the right PCB manufacturer for a product is not that easy, and for certain layouts, what were once more complex specifications for a PCB have now become standard. Technical queries from the manufacturer are usually answered directly by the PCB designer and the manufacturability of the PCB production is discussed with the manufacturer in relation to the complex layout.

Technical office

The PCB designer works with the technical office on a range of topics. This may be to prepare a quotation for a customer, estimating the production size of the PCB in order to calculate the processing time, checking an SAP bill of materials for the assembly and mounting of the PCB, or maintaining existing products.

Project management

Close cooperation with the project manager makes it possible to keep to the schedule and avoid delays due to a PCB being delivered too late. The PCB designer is also involved in customer communication during series production if certain changes are planned in the layout or if suggestions are requested on how the product design can be implemented more cost-effectively, more simply or more conveniently for production.

Incoming goods

To ensure that the PCBs received have been correctly delivered, the PCB designer helps the incoming goods department to check the correctness and quality of the PCBs supplied.

Production

It is absolutely essential to work together with the production department at an early stage to develop a PCB layout, regardless of whether the circuit board will later be processed in SMD or THT production. The designs that are implemented must, first and foremost, be producible. It is therefore of the utmost importance to discuss the possibilities of a placement machine, solderability of the component, quality of the circuit board, distances between components and much more with the production department. For subsequent series production, the PCB designer provides the necessary data for the placement machines, SPI, AOI and manual assembly.

Electronics laboratory

At the beginning of the design process, electronics engineers often need a sample PCB very quickly in order to test the developed circuit. To speed up this process, STEINEL assembles prototypes in-house in small quantities and tests them in its own EMC laboratory. The electronics laboratory and the PCB designer work together on solutions and optimisations for a functional, producible PCB design.

Quality management

If there are production problems with the printed circuit board or with the placement of electronic components, the PCB designer is involved in the joint process of finding a solution between the departments. The PCB designer also provides specialist support to the quality department when analysing incorrectly delivered printed circuit boards.

Sales

The collaboration between the sales team and the PCB designer means that any special customer requests can be assessed in advance, thus avoiding certain misunderstandings when drawing up an indicative offer. The PCB designer also provides technical support for circuit board-specific questions.

Customers

In most cases, questions from the customer are answered by the customer-facing contacts in the sales, project management or technical office. If the questions are technically more in-depth, the electronics development and PCB designers are available to clarify the open points directly with the customer. In certain projects, the PCB designer even works very closely with the customer.

The many interfaces show: at STEINEL, the PCB designer is not "just" a layout designer, but also a team player, solution finder, coordinator, reviewer, listener and supporter for the various departments. It's all about the printed circuit board and how it creates a successful product.

Portrait of the employee who wrote the article

"Our customised OEM products and projects are a constant source of challenges for me and make my job very varied. It is my job to dutifully implement all rules and standards and create a functioning PCB design so that the circuit board is suitable for production and the product is a success – and all in an interface role."

Andreas Höhn, Head of PCB Design & Electronics Development Laboratory at STEINEL Solutions AG