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PCB Design Variants: Managing Multiple PCBA Versions

Product variations often require different component populations, alternate parts, or configuration settings while keeping the underlying PCB design unchanged. This article explains how structured variant management keeps these differences organized and ensures each configuration has the correct BOM and manufacturing outputs.

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Embedded thumbnail for  Improve Visual Accuracy with True Arcs
New in Altium's Software
Improve Visual Accuracy with True Arcs

Discover how True Arc Rendering improves arc visualization in the PCB Editor and PCB Library Editor by displaying true arcs across 2D, 3D, and Board Planning modes. This provides a more accurate representation of board geometry and helps you work with curved features with greater precision throughout the design process.

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Collaborative Engineering with Team Ribbot
Two engineers, one board, nobody's work gets wiped out

When Team Ribbot’s electrical and mechanical engineers work on the same combat-robot design, unwanted changes can mean hours of lost work. See how Altium Designer and MCAD CoDesign let the team review and selectively accept changes, enabling seamless parallel collaboration across different locations and schedules.

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New in Altium's Software
Visualize and Refine Your Harness Designs

Create detailed views of bundle contents, control wire and cable paths, and rotate physical models to accurately represent the final harness assembly. These capabilities give you greater control over harness design and help ensure your digital model reflects the physical result.

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New in Altium's Software
Introducing Agentic Requirements Engineering

Discover a new way to work with Requirements Portal through Agentic Requirements Engineering. AI agents analyze your project data and surface proposals for your approval, reducing friction in requirements management and helping align your team's shared model with your design intent.

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New in Altium's Software
Simplify Rule Set Updates and Replacement

Learn how to import rule sets with greater flexibility in Altium. When importing rules, you can add new rules to your existing set, replace only rules that match, or completely replace the current rule set giving you full control over how design rules are updated.

Embedded thumbnail for  How Team Ribbot fits 40 kW of power into a 250-pound combat robot
Collaborative Engineering with Team Ribbot
How Team Ribbot fits 40 kW of power into a 250-pound combat robot

What do you get when you pack the power of a small electric car into a combat robot with virtually no room to spare? In the first episode of our collaboration with Team Ribbot and Altium, explore how seamless ECAD-MCAD collaboration helps the team tackle complex design challenges, optimize high-performance designs, reduce errors, and bring products to life faster.

Embedded thumbnail for Just Released: Supplier Data Merging
New in Altium's Software
Just Released: Supplier Data Merging

Discover how the Supplier Data Merging feature brings together supplier information from your custom parts database and the Altium Parts Provider into a single, unified view. Access consolidated supplier data wherever supplier part numbers appear, including in ActiveBOM and during component selection.

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How-To's
How Altium’s Layer Stack Manager Actually Works

Take a look inside Altium's Layer Stack Manager and discover how its impedance calculator determines the ideal trace width for your target impedance. In this video, we break down the "black box" behind the calculation and show how the Simbeor-based field solver provides accurate results while eliminating the need for advanced field solver expertise.

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New in Altium's Software
Connect Requirements Directly to Your PCB Design

See how the Requirements Portal integration in Altium Designer simplifies requirements management by bringing system requirements directly into your PCB design workflow. Connect requirements to design documents, assign tasks, track verification in real time, and keep your entire team aligned with seamless synchronization in Altium 365.

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How-To's
SFP Connector Routing: High-Speed Differential Pair Design Tips

Discover practical SFP and SFP+ routing tips in our latest video, inspired by a real question from the Altium subreddit. We cover how aggressive serpentine length tuning can be, how to reduce impedance discontinuities in tight meanders, and how meandering influences mode conversion at 10G and higher data rates.

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electrical circuit with microcontroller
Blog
Designing Custom Hardware with Microcontrollers

In this article, we’ll look at all that is required to start creating your own custom microcontroller-based hardware designs. You’ll see that there actually isn’t too much to this, as microcontroller manufacturers over the years have tried to make the learning curve less steep and their devices more, and more accessible. This is both from an electrical point of view but also – equally importantly – from a programming point of view.

high-speed printed circuit board
Blog
Guide to Low-Dk PCB Materials

If you’ve taken time to learn about PCB material options and layer constructions, you have probably seen the wide range of materials that are available on the market. Materials companies produce laminates with varying Dk values, Tg values, weave styles, CTI values, and mechanical properties to target various applications in the electronics industry.

freeway in the background of the city
Blog
Designing for V2X Communication: Wireless Protocols and Standards

If you’re waiting for truly connected cars on a grand scale, there is still a massive amount of work to be done, both on the hardware and software sides. Connected cars can only become a widespread reality once the automotive industry and telecom carriers can decide which protocol will work best for vehicle-to-everything (V2X) communication. PCB designers will then need to step in to create these systems and fit them into a vehicular environment.

Everything You Need to Know About Stitching Vias
Blog
Everything You Need to Know About Stitching Vias

This one area of PCB design can be contentious among some designers as it is related to copper pour, which it is often stated is not needed in most designs. Regardless of your feelings about copper pour, stitching vias have important uses in PCBs at low frequencies and at high frequencies.

All About Box Build Assemblies
Blog
All About Box Build Assemblies

When you’re ready to manufacture a new device at production volume, there are many aspects of the product that must come together. The enclosure, cabling and connectors, embedded software/firmware, and of course the PCBA all have to be considered in totality. There is a quick way to get your product into a usable enclosure, complete with input power and cabling, and with a form factor that fits your PCBA. This overused route to a new product is a box build assembly. 

Ultra-HDI Technology is Not New
Blog
Ultra-HDI Technology is Not New

Printed circuit board fabricators have become skilled at manufacturing these technologies and also at understanding the reliability and producibility challenges associated with high-density-interconnect technology. Let’s look at where the PCB industry is at today. 

Today's PCB Designers Are Driving Electronics Product Design
Blog
Today's PCB Designers Are Driving Electronics Product Design

What can the industry do to support PCB designers as they continue taking a more active role in product development? Here at Altium, there has been a progressive shift towards looking at the system level and creating tools that get designers more involved throughout the product development process. As the saying goes, over the wall engineering is over… today’s most successful products are built in a collaborative process.

Phased Array Antenna Design for 5G Applications
Blog
Phased Array Antenna Design for 5G Applications

As the 5G rollout progresses and researchers continue to discuss 6G, many new 5G-capable products operating in sub-GHz and mmWave bands are reaching the marketplace. Devices that will include a 5G-compatible front-end, whether small stations/repeaters or handheld devices, use phased arrays as high-gain antenna systems to provide high data throughput without losing range at higher frequencies.

IPC - Vias
Blog
IPC - Vias

Via protection is an important part of modern PCB design. It provides additional benefits in PCB manufacturing and assembly, increasing the number of acceptable products.

Power Integrity Analysis in Your PCB Design Software
Blog
Power Integrity Analysis in Your PCB Design Software

Power integrity problems can abound in modern PCBs, especially high-speed boards that run with fast edge rates. These systems require precise design of the PDN impedance to ensure stable power is always delivered throughout the system.

Schematic Compare
Blog
Schematic Compare

A design project doesn’t appear out of nowhere. The design process spreads over time, and project documents change. Schematic documents gradually become more complex, new functional blocks appear, and already finished parts can be modified and updated.

Embedded Capacitance Materials Overview
Blog
Embedded Capacitance Materials Overview

Capacitance is your friend whenever you need stable power integrity, which is why there is so much focus on decoupling capacitors. While these components are important and they can be used to provide targeted power integrity solutions to certain components, there is one specialty material used to supercharge capacitance in your PCB stackup or package substrate. 

How To Import Libraries and Manage Components With Altium 365
Blog
How To Import Libraries and Manage Components With Altium 365

The problems you can experience with components and libraries are endless. These problems are the most significant source of design issues and the biggest reason behind respins, costing companies untold amounts of lost profit annually.
If you want to have a better understanding of how to use Altium 365 to maintain a strong and centralized library that is free of problems and headaches, you may want to consider attending this lecture.

The High-Speed PCB Stackup Design Challenge
Blog
The High-Speed PCB Stackup Design Challenge

As much as we would like to build every high speed PCB perfectly, with ideal SI/PI/EMI characteristics, it isn’t always possible due to many practical constraints. Sometimes a stackup can be “good enough,” even for a high-speed PCB. This always comes from the need to balance engineering constraints, functional requirements, and the need to ensure signal and power integrity in a high-speed design, and finally to ensure compliance with EMC requirements.

How I Improved My Collaboration Efficiency with Altium 365
Blog
How I Improved My Collaboration Efficiency with Altium 365

Involving the whole team that will bring a product to completion early on in the development cycle is vital to efficient development. Design reviews with all the relevant parties are critical at each step of the design process, starting with high-level component selection, then through the schematic capture and PCB layout stages. 

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Embedded thumbnail for How to Use the MCAD CoDesigner?
How-To's
How to Use the MCAD CoDesigner?

This video shows how the ECAD and MCAD engineers now can communicate directly while staying within their own design environment. The MCAD engineer is able to push design information directly from their design software straight into Altium Designer. Any changes can be reviewed, accepted, or denied by the receiving party. This process of pushing and reviewing design changes is bi-directional, meaning that both the MCAD or ECAD engineer can push and review changes to the other. 

Embedded thumbnail for Creating Additional Snap Points Using a 3D Model
How to use Snapping
Creating Additional Snap Points Using a 3D Model

Demonstration of using snap points with 3D models and how they can assist in the placement of said models.

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Working with Polygons
Polygon Connect Styles

Define how vias and pads connect to polygons with a design rule. Customize the thermal relief width, number, and rotation as well as the air gap width.

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How to Work with Classes
How to work with Component Classes?

Modern printed circuit boards can contain a large number of components, which makes them difficult to work with. In this video we will show what component classes can be on a PCB, how to create custom component classes and how they can be useful for us. 

Embedded thumbnail for Create and Snap to a Circular Grid (Polar Grid)
How to use Snapping
Create and Snap to a Circular Grid (Polar Grid)

Instructional on how to create polar grids, how to snap to them, and why you might want to use them.

Embedded thumbnail for How to Connect Polygons to Nets
Working with Polygons
How to Connect Polygons to Nets

This video covers how to easily connect a polygon to a net using just two clicks. With the Properties panel open and a polygon selected, click the "Assign net" button in the Properties panel.

Embedded thumbnail for Altium 365 Getting Started: Gerber Compare
Getting Started with A365
Altium 365 Getting Started: Gerber Compare

The task of comparing different versions of manufacturing files usually arises when the electrical engineer needs to check and confirm the manufacturer's edits or clarify details of changes before starting production. In Altium 365 you can perform an automatic comparison of Gerber files. 

Embedded thumbnail for Altium 365 Getting Started: Migrate to Altium 365 from other VCS
Getting Started with A365
Altium 365 Getting Started: Migrate to Altium 365 from other VCS

The development of electronic devices always involves the release of many different types of files. And these files are not static - they change as the project progresses. Traditionally, one way to manage data is to use a version control system such as Git or SVN. Unlike other VCSs, Altium 365 is the system designed specifically for managing project data.

Embedded thumbnail for How to get a BOM for a Multi-board Design
How-To's
How to get a BOM for a Multi-board Design

When designing a multi-board project, an up-to-date and accurate BOM for the entire device is a necessity. Watch this video to learn how to properly create a BOM for your multi-board project.

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Working with Polygons
Remove Unused Pad Shapes

Unused pad shapes create holes in your copper geometries. You can quickly examine all pads in the design to remove unused pad shapes and restore previously removed pads. 

Embedded thumbnail for Effective use of "Objects for snapping" when creating a Footprint
How to use Snapping
Effective use of "Objects for snapping" when creating a Footprint

Learn how to effectively use snaps that allow you to create a component footprint quickly and conveniently

Embedded thumbnail for How to Control Routing in Altium Designer
How-To's
How to Control Routing in Altium Designer

The routing functionality in Altium Designer is constantly evolving. Check out this video to learn the basics of routing in Altium Designer. 

Embedded thumbnail for Polygon Creation
Working with Polygons
Polygon Creation

Learn how to create polygon pours to ensure proper copper distribution on your board.

Embedded thumbnail for Creating Guide Lines and Snap Points
How to use Snapping
Creating Guide Lines and Snap Points

Explanation of guides and snap points and how to create and use them.

Embedded thumbnail for Polygon Types and Parameters
Working with Polygons
Polygon Types and Parameters

Each board requires different copper geometries. Polygon types make sure you can create the perfect copper geometry for every need.

Embedded thumbnail for How to Define Different Clearance for Internal and External Layers
How-To's
How to Define Different Clearance for Internal and External Layers

If you need to define difference clearance values for your external and internal layers, the answer is with design rules. We’ll walk you through it in this short video. 

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Integrating Requirements June 2025 Webinar
On-Demand Webinar Mai 28, 2025
Integrating Requirements into Your PCB Design Workflow
Join our webinar where you will learn about integrated requirements tools who can help you eliminate late-stage design changes, AI support through system requirements and integration of design requirements directly in PCB Design. Don't miss it, register now!
Streamlining Team Collaboration
On-Demand Webinar Apr. 17, 2025
Streamlining Team Collaboration in Industrial PCB Projects
Join us for our upcoming webinar to discover how Altium Designer and Altium 365 can transform your team’s collaboration and take your PCB design projects to the next level. Attend for a chance to win free access to the Altium 365 Training Bundle.
PCB CoDesign Webinar
On-Demand Webinar Jan. 24, 2024
Discover How Altium Designer 24 Revolutionizes Team Dynamics in PCB Design
Expand your collaboration skills and stay ahead of the curve with PCB CoDesign. Design teams often grapple with prolonged design cycles and coordination issues, leading to delays and inefficiencies. In the current landscape, design processes are hindered by fragmented collaboration, resulting in increased layout times and difficulties in synchronizing design updates.