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The PCB Fabrication Process — what Every Design Engineer Needs To Know, Part 2

In Part 1 of this article, I described the first steps that occur during the PCB fabrication process. They detailed the inner layer processing effort as well as the efforts that take place during the transition from inner layer processing to lamination. This part of the article will provide a detailed description of the lamination, drilling and plating processes.

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The PCB Fabrication Process—What Every Design Engineer Needs To Know, Part 1

There are still a number of designers - perhaps most of them - who have never toured a PCB fabrication facility. They are also unaware of the various steps that occur during the fabrication process. The purpose of this article is to describe those steps and what transpires in each of them. Part 1 of this article focuses on inner layer processing and the steps that are done prior the lamination process.

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Blog
Webinar "8 Reasons to Store Your Components in Altium 365"

Working with local libraries seems like a simple solution, but we often don’t take into account the added time spent maintaining libraries and sharing them between team members. This webinar showcases the advantages of component storage in Аltium 365 to resolve the issues of local libraries and component management.

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Bridging the Gap Between Designers and Customers

Every piece of electronic equipment starts with a great idea. Transforming great ideas into real, physical products takes a team of talented individuals and multiple companies coming together to make everything from the internal components to the external hardware. Paul Payen de la Garanderie, Founder and Owner of AW Audio, an engineering services company based in France, understands these challenges very well. With an extensive background in the Audio/Visual industry, Paul has had to work with multiple companies over the years, from small start-ups to celebrated AV firms.

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Additive PCB Manufacturing: The Vaccine for Electronics Supply Shocks?

At this time, at least a quarter of the world’s population is under quarantine, with workers unable to go to offices or factories, leading to fundamental disabling of the world economy. The electronics industry is suffering greatly as well, dealing with a supply shock from factories shutting down in Southeast Asia, to demand-side shocks from Western markets literally shutting down. Now it is the electrical engineers taking the lead with additive PCB manufacturing.

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Webinar "6 Steps to Master Project Storage"

Altium 365 provides a secure cloud platform to store all of your design files in a single place so you can share them with anyone and access them from anywhere. This webinar discusses the advantages of placing, storing, and working with projects in Altium 365.

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Blog
Altium Designer 20 Changed My Layout Design Routines

I just finalized my first PCB design using Altium Designer 20. At the same time, I tested some new AD20 features, and in this article, I’ll share my thoughts about new layout design features which made the biggest impression for me: sliding, and any-angle routing.

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Blog
Designing for Antenna Isolation in Your Wireless System

Anyone who has taken apart an old cell phone or designs IoT devices knows multiple communication capabilities are present in these designs, each requiring different antennas. The RF designer should already take precautions for interconnect isolation, but antenna isolation is just as important when modeling and designing wireless systems.

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PCB Trace and Pad Clearance: Low vs. High Voltage

High voltage/high current designs carry safety requirements which need to be met by designers. Similarly, high speed designs need to have suppressed crosstalk in order to ensure signal integrity. The key design aspects that relate to both areas are your PCB trace clearance and pad clearance values. These design choices are critical for balancing safety, noise suppression, and manufacturability.

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Getting Through PCB DFM

In this article, we’ll discuss the key design features to implement, and steps to take prior to fabrication that will help prevent some DFM process pain.

Altium Designer Getting Started User Guide
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Level Up Your Design Skills - Altium Designer Getting Started User Guide Update
We are happy to announce the new update of our Altium Designer Getting Started User Guide. Whether you are new to Altium Designer or you want to brush up on some topics, the Altium Designer Getting Started User Guide will take you from a beginner to a master in PCB design.  This is only the beginning! This guide will be updated with new information based on user feedback. Let’s first go over the contents of the guide.
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Discovering Altium 365
Design Review Use Case

Design reviews are critical to being successful. Capture design discussions through contextual commenting in the web browser or in Altium Designer to ensure feedback is recorded and actioned effectively.

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Modeling Copper Foil Roughness in Altium Designer's Impedance Profiler

With the new layer stack manager in Altium Designer®, you can now include copper foil roughness factors directly in your impedance calculator. This is quite easy to do in the layer stack manager, but it begs the question: what exactly is the copper roughness factor? Which value should be used for your interconnects?

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Resolving Errors in the PCB

We’ve looked at how to set up the Design Rule Checker to help us analyze our PCB design errors. Now it’s time to resolve these errors and prep our design to start generating output files.

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High-Speed Signal Routing: The 5 Important Constraints

After you capture your schematic as an initial layout and create an initial component arrangement, it’s time to define your routing constraints. Doing this early will allow your DRC engine to spot rules violations before you finish your layout. Likewise, you’ll be able to modify the default rule set to meet your layout requirements. Here are the important routing constraints you’ll need to check before you start routing your board.

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How to Create a PCB Manufacturing Cost Estimation

Some manufacturers have very convenient PCB manufacturing cost estimation calculators you can use, but the real costs depend on a number of factors. If you’re an entrepreneur and you’re producing your own boards, or you are managing manufacturing, testing, and delivery for a new project, it’s your job to help clients understand the primary cost drivers for new boards. Here’s how you can get an estimate of your fabrication costs, both for local and overseas manufacturers.

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Defining the Layer Stackup

The PCB is designed and formed as a stack of layers and the definition of the PCB layer stack is a critical element of successful printed circuit board design. In Altium Designer, the Layer Stack Manager is used to develop the printed circuit board internal design including layer-pairing, careful via design, any back drilling requirements, rigid/flex requirements, copper balancing, layer stack symmetry, and material compliance. This video guides you through creation of a layer stackup, adding the necessary layers, as well as adding an impedance profile.

Blog
PCB Mountable Connectors: SMD vs. Through-hole

Selecting a connector is as much an art as it is a science. The artistic side is all about aesthetics and satisfying clearances, while the scientific side is all about signal integrity. For PCB mountable connectors, you’ll need to choose between surface-mounted or through-hole connectors, and you’ll need to consider how each type affects signal integrity in your application. Here’s what you need to think about beyond the standard connector specifications.

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PCB Via Current-Carrying Capacity: How Hot is Too Hot?

Trace and via current-carrying capacity are legitimate design points to focus on when designing a new board that will carry high current. The goal is to keep conductor temperatures below some appropriate limit, which then helps keep components on the board cool.

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Ground Below SMPS Inductors
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Should Ground Be Placed Below Inductors in Switching Regulators?

We love answering questions from our readers and YouTube viewers, and one of the recent questions we received relates to EMI from switching elements in a switching regulator is "Should a cutout be placed below the inductor in a switching regulator circuit?". Despite the variations in inductors and their magnetic behavior, there are some general principles that can be used to judge the effects of placing ground near inductors in switching regulator circuits. We’ll look at some of these principles in this article

Alternative Pins
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Altium Designer 22.6 Update

We are happy to announce that the Altium Designer 22.6 update is now available. Altium Designer 22.6 continues to focus on improving the user experience, as well as performance and stability of the software, based on feedback from our users. Check out the key new features in the What's New section on the left side of this window!

Top 5 Questions Regarding Stack Up
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SAP (Semi-Additive PCB Process) – Top 5 Questions Regarding Stack Up

This Semi-Additive Process is an additional tool in the PCB fabricators' toolbox that enables them to provide feature sizes for trace width and spacing that are 25 microns, (1 mil) and below depending on the fabricators' imaging equipment. This provides much more flexibility to breakout out tight BGA areas and the ability to shrink overall circuit size and/ or reduce the number of circuit layers in the design. As the PCB design community embraces the benefits of this new printed circuit board fabrication technique, there are of course many questions to be answered.

Three ways to manage your BOM costs
Blog
Improving Supply Chain Success with BOM Management

It’s no secret that component shortages have become more frequent this year. In fact, countries around the world are losing billions in revenue due to supply issues. Having the right components on hand is more crucial than ever as availability, obsolescence, counterfeit products and environmental non-compliance risks continue to grow. Fortunately, many shortages can be avoided by introducing proactive supply chain practices.

Length Tuning Impedance
Blog
What is the Impedance of Length-Tuning Structures?

Do length-tuning structures create an impedance discontinuity? The answer is an unequivocal “yes”, but it might not matter in your design depending on several factors. Applying a length-tuning structure is equivalent to changing the distance between the traces while meandering. Therefore, you will have a change in the odd-mode impedance of a single trace. The question then becomes: does this deviation in trace impedance in a length tuning structure matter?

Designing the Next-Generation Electronics
Blog
A-SAP™ – What do you need to know?

The continued miniaturization of both packaging and component size in next-generation electronics is becoming harder and harder to work around and presents a significant challenge for both PCB designers and PCB fabricators. To effectively navigate the constraints of the traditional subtractive-etch PCB fabrication processes, PCB designs require advanced PCB fabrication capabilities while pushing the limits of finer feature size, higher layer counts, multiple levels of stacked micro vias and increased lamination cycles.

Pin-package and Via Delay Values
Blog
Pin-Package Delay and Via Delay in High Speed Length Tuning

Take a look at the inside of some integrated circuit packages, and you’ll find a number of wires bonded to the semiconductor die and the pads at the edge of the component's package. As a signal traverses makes its way along an interconnect and into a destination circuit, signals need to travel across these bond wires and pads before they are interpreted as a logic state. As you look around the edge of an IC, these bond wires can have different lengths, and they incur different levels of delay and contribute to total jitter.

6-Layer PCB Design
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6-Layer PCB Design Guidelines

Once you’ve run out of room on your 4-layer PCB, it’s time to graduate to a 6-layer board. The additional layer can give you room for more signals, an additional plane pair, or a mix of conductors. How you use these extra layers is less important than how you arrange them in the PCB stackup, as well as how you route on a 6-layer PCB. If you’ve never used a 6-layer board before, or you’ve had EMI troubles with this stackup that are difficult to solve, keep reading to see some 6-layer PCB design guidelines and best practices.

Altium Designer Interface
Blog
Altium Designer 22.5 Update

We are happy to announce that the Altium Designer 22.5 update is now available. Altium Designer 22.5 continues to focus on improving the user experience, as well as performance and stability of the software, based on feedback from our users. Check out the key new features in the What's New section on the left side of this window!

Are Hybrid PCB Stackups Reliable?
Blog
How Reliable is Your Hybrid PCB Stackup?

PCB stackups often incorporate slightly dissimilar materials that could pose a reliability problem. Hybrid PCBs are one case where the PCB stackup will include different materials, typically a standard FR4 laminate and a PTFE laminate for RF PCBs. Designers who want to take the lead on material selection when designing their hybrid stackups should consider these factors that affect reliability. As with any PCB stackup, make sure you get your fabricator involved in the manufacturing process early to ensure reliability problems do not arise during production.

Monte Carlo vs Sensitivity Analysis
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Monte Carlo Simulation vs. Sensitivity Analysis: What’s the Difference?

In a previous article about circuit simulation and reliability, I looked at how Monte Carlo analysis is commonly used to evaluate circuits that are subject to random variations in component values. Sensitivity analysis is a bit different and it tells you how the operating characteristics of your circuit change in a specific direction. Compared to a Monte Carlo simulation, sensitivity analysis gives you a convenient way to predict exactly how the operating characteristics will change if you were to deliberately increase or decrease the value of a component.

Simulation, Build and Test
Blog
Creating Continuous Integration Pipelines for FPGAs

Field Programmable Gate Arrays, or FPGAs, have become ubiquitous amongst high-speed, real-time digital systems. The speed at which FPGAs operate continues to increase at a dizzying pace but their adoption into Continuous Integration pipelines seems not to trail as closely. In this article we will review the concept of CI pipelines, their application to FPGAs, and look at examples on how to set this up.

Collaborators Visualization
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Soft Locks [Conflict Prevention] in Altium 365

Conflicts can occur when multiple people work on the same project simultaneously. The user might not realize that they are not looking at the latest version of the documentation, leading to problems later. To address this issue, Altium features an intuitive graphical user interface that allows you to examine conflicts quickly and carefully

Guide to Monte Carlo in SPICE
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The Basics of Monte Carlo in SPICE: Theory and Demo

Anytime you place a component in your PCB, it’s almost like you’re gambling. All components have tolerances, and some of these are very precise, but others components can have very wide tolerances on their nominal values. In the event the tolerances on these components become too large, how can you predict how these tolerances will affect your circuits?

BGA Land Patterns and Footprints
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What's In Your BGA Land Pattern and Footprint

If you look in datasheets for most components, you’ll often find a recommended land pattern, usually alongside some mechanical package information and assembly information. This is not always the case with BGA components, especially components with high ball count. There are a few reasons for this that we can speculate: those ball counts might just be too big to put into a single page, or the manufacturer just expects you to know how to create that land pattern.

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Embedded thumbnail for Take 66% of Your Time Back with Custom Pad Stack in Altium Designer 25
Altium Designer's 25 Quantitative Benefits
Take 66% of Your Time Back with Custom Pad Stack in Altium Designer 25

This video demonstrates the measurable productivity gains of using the Custom Pad Stack tool in Altium Designer 25. It compares a detailed QFN-32 footprint customization process across versions, showing a significant reduction in time and mouse clicks—2 min 5 sec vs. 6 min 2 sec, and 45 vs. 116 clicks.

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How-To's
PCB Stackups in Reverse?

Watch our new tutorial on reverse PCB stackups — a unique approach that combines thin internal layers with thicker outer cores for specialized applications. Learn how to implement reverse stackups effectively in Altium Designer, understand key manufacturability constraints, and explore Rogers materials specifically suited for this technique.

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New in Altium Designer 25
Design Smarter - Harness, Multi-board, and MCAD CoDesign in Action

This webinar highlights how Altium Designer 25, with a Pro or Enterprise subscription, enables seamless ECAD-MCAD collaboration using Harness and Multi-board Design tools and the advanced MCAD CoDesigner. Viewers will learn how to integrate harness designs, optimize multi-board systems for enclosure fit, and synchronize designs with SolidWorks, PTC Creo, and Autodesk Inventor.

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New in Altium Designer 25
Unified Login in Altium Designer 25

We've unified the login experience across Altium Designer, Altium 365, and the Altium website—one set of credentials is all you need. This update simplifies access, enhances security, and improves session management for a smoother user experience.

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How-To's
Custom Ethernet Switch Powers Up: Assembly to Working Hardware Test

Watch our latest video as host Zach Peterson presents his custom Ethernet switch PCB. He walks through the design in Altium Designer, programs the firmware, and tests the board in a real server environment using both copper and fiber connections. This video showcases the complete journey from PCB design to fully functional hardware.

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How-To's
Mastering Pad and Via Templates (or Padstacks) in Altium Designer

Learn how to create, export, and reuse Pad and Via templates (Padstacks) in Altium Designer. This tutorial covers standardized libraries to optimize PCB design and ensure consistency across projects.

Embedded thumbnail for Power Rail Routing Mastery: Multiple Voltage Planes in Altium Designer
How-To's
Power Rail Routing Mastery: Multiple Voltage Planes in Altium Designer

Want to design a complex Power Distribution Network (PDN)? Watch our exclusive tutorial to learn expert techniques for routing 10+ power rails on a single PCB layer—while minimizing EMI and ensuring signal integrity.

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Altium Designer's 25 Quantitative Benefits
Unveiling 99% Task Time Efficiency

This video showcases Altium Designer 25’s PCB Section View, a powerful tool for detailed circuit analysis and optimization. Learn how it enhances precision, improves performance, and simplifies complex PCB layouts with real-world applications.

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How-To's
Bottom Terminated Component Guide: Footprint Design Best Practices

Want to create a reliable footprint for your PCB design? Watch our latest video with Zach Peterson and learn best practices for designing PCB footprints for bottom-terminated components. This tutorial covers how to properly design paste masks for QFNs, BGAs, and other bottom-terminated packages to prevent common assembly issues.

Embedded thumbnail for Design 4x Faster with Altium Designer 25
Altium Designer's 25 Quantitative Benefits
Design 4x Faster with Altium Designer 25

PCB CoDesign in Altium Designer 25 enables multiple engineers to collaborate on a single PCB design, saving over 10 minutes and 300+ clicks. With an intuitive compare-and-merge workflow, teams can efficiently resolve conflicts and streamline their design process. Check out this video to learn more, and use the Benefit Calculator to see your potential time savings: https://www.altium.com/benefit-calculator.

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New in Altium Designer 25
Empowering Hybrid Designs with Wire Bonding

Our latest whitepaper on Wire Bonding technology is now available! It explores the role of wire bonding in modern PCB design and how Altium Designer 25 enhances the process with dedicated features. Access it here: Wire Bonding Whitepaper.

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Altium Designer's 25 Quantitative Benefits
8 Times Faster Simulations Using Altium Designer 25

Speed up your simulations with Altium Designer 25—now up to 8x faster! Watch our comparison to see how built-in simulation slashes processing time, saving you valuable minutes on every task.

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New in Altium Designer 25
Harness Design Top 5 Improvements in Altium Designer 25

Harness Design in Altium Designer 25 just got a major upgrade! This video showcases the top five new features that improve flexibility, organization, and efficiency in your wiring workflow. Watch now to see these enhancements in action and take your designs to the next level!

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Altium Stories
HitIQ uses Altium solutions to better understand brain injuries in sports sciences

Watch our video about HitIQ and theirs usage of Altium's software to develop a Smart Mouthguard, an advanced concussion management solution. Our software accelerated their development, improved accuracy, and its helpful for detecting and managing sports-related brain injuries.

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New in Altium Designer 25
Boost Team Productivity with Seamless Collaboration - Recording Preview

Discover how to enhance your PCB design workflow with Altium Designer and Altium 365. Learn to speed up tasks, enhance collaboration, connect teams, and optimize part selection—all in one seamless environment.

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How-To's
Altium Tutorial: Harness Design to Multi-Board Assembly Workflow

Watch our latest tutorial on Harness Design and Multi-board, where we showcase best practices for Harness Design, MCAD collaboration, and manufacturing documentation generation to enhance your PCB assembly workflow.

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