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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.

NEW
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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Sharing Settings in Altium 365
Blog
Granular Sharing — Role and Group Management

With Altium 365, you can grant permission to teams or users based on the specific needs of a project. We have expanded Altium 365’s file-sharing setting, giving you more granular control over who can download source files and reshare projects with others

Use your DRCs
Blog
Design Rule Checking in the PCB Design Workflow

Any time you design a PCB, and you want to turn it into a real product, you will have to make sure the design obeys the constraints within the standard PCB manufacturing process. This imposes multiple rules on any design, and ECAD software will enforce design rules as you create the board to ensure you obey these important constraints. Make sure you enforce the right design rules at the beginning of the PCB design workflow 

How to select high frequency materials
Blog
Best Practices for High-Frequency PCB Material Selection

High frequency PCB design can seem esoteric, and I've heard many an engineer describe it as "black magic"! The subject is also a bit confusing, especially once someone asks which frequencies could be reasonably considered "high". Before you do anything inside the layout for a high-speed or RF PCB, you will need to pay attention to the materials being used in the board. If you're unsure which high frequency PCB materials you should use, then keep reading to learn more.

PCB Noise Reduction
Blog
PCB Noise Reduction: Do You Need Isolation, Shielding, or Filters?

Of all the noise and operational challenges designers face in their PCBs, there is one overarching problem that is arguably most popular: electronic noise. It could originate as an SI/PI problem, it could possibly arise from some external source, or it could be good old-fashioned crosstalk! These tend to fall into three categories: adding shielding, doing something to create isolation, or placing filters. Let's look at all of these as they tend to be the default solution set when confronted with many noise problems.

What’s New in Altium 365
Blog
What’s New in Altium 365: Version Control for Hardware, Layer Stackup in Web Viewer, and SOC 2 Type 1 Certification

In February, we hit a new record in the number of users on the platform. The Altium 365 user community is now 20,000 strong! You can now migrate from an external version control system to Altium 365 preserving the history of commits. We also received the SOC 2 Type 1 certification from KPMG, made layer stack available in the web viewer, and added the brand new capability to track tasks in the context of your design project. Keep reading to learn more!

Rigid-Flex in Altium Designer
Blog
Support for Rigid-Flex in Altium Designer

Rigid-flex in Altium Designer starts with designing a manufacturable PCB layer stack complete with via transitions and any calculated impedance requirements. Flex sections also need to be placed in the layer stack before moving into the PCB layout. Once inside the PCB editor, bending lines can be clearly defined in the PCB layout, and these can be visualized in Altium Designer's 3D PCB design tools. Keep reading to see how Altium Designer supports your flex and rigid-flex designs.

Specifying your stackup
Blog
Communicating PCB Layer Stackup Needs to Manufacturers

In the business of PCB design, communicating needs to manufacturers and vendors is a top priority. The context of our requests is sometimes lost either by not providing the correct information, not listing enough information, or not giving any information. Although the experienced PCB designer can take steps to specify everything they want to see in their PCB stackup, eventaully the manufacturer will handle that decision in an effort to balance available materials with processing capabilities and yield.

Risk Vs. Reward
Blog
Risk Vs. Reward

During the recent IPC APEX expo, there was a lot of discussion about SAP, or semi-additive PCB processes.  As with any new technology adoption there were people that are excited to jump right in and start designing with much finer feature sizes and work through the inevitable changes to the traditional thought process. Others are in a "let’s wait and see" mode and of course there are a few skeptics there as well, so keep reading to learn more.

Parasitic Extraction for your traces
Blog
Parasitic Extraction with an Electromagnetic Solver in PCB Routing

Parasitic extraction: the integrated circuit design community must grapple with this task on a daily basis, especially once gate features are reduced below ~350 nm and chips run at high switching speeds. The PCB community also has to deal with this idea in order to better design power delivery networks, interconnects with precise impedance, and properly quantify crosstalk and coupling mechanisms.

PCB
Blog
Ebook: PDN Simulation and Analysis Guide

Most designers don’t realize they need to worry about power integrity until they have a power integrity problem. Other designers might build boards that can’t handle the demands of modern digital and high frequency components, and they may not realize the problems that lurk in their power delivery network (PDN). Although the basic concepts involved in designing for power integrity are well-known, myths about power integrity abound, and designers need tools to help them evaluate and qualify power integrity in a PDN.

Ferrites in PDN Simulation
Blog
Ferrite Beads and Transfer Impedance in a PDN Simulation

The use of ferrites in a PDN is one design recommendation that is fraught with unclear guidance and over-generalized recommendations. If you see an application note or a reference design that recommends placing a ferrite in a PDN, should you follow this in your specific design, or should you ignore this and focus on adding capacitance? 

PCB Design Outputs
Blog
Overview of PCB Design Output Files

Before your board can be put into production and prepared for assembly, you have to generate a set of files that assist your manufacturer. These are your PCB design output files, also known as manufacturing files, fabrication data, assembly files, and a host of other names. Before you send your design file off to a manufacturer in an email, make sure to get a list of their required fabrication and assembly files first. If you’re a new designer, take some time to read over the basic PCB manufacturing file extensions below.

How transformers work
Blog
Transformer Theory Made Simple

Transformers can provide very effective signal isolation and are used to manipulate AC voltage and current levels. They can achieve all this with a greater than 95% power efficiency, which is why we commonly see them used in bench power supplies, audio gear, computers, kitchen appliances, and wall-warts. However, transformer theory can be unintuitive and in this article we answer on questions about them

Take advantage of the VCS-based workflow in Altium 365
Blog
Using Altium 365 Over Your Vanilla Version Control System

There are all sorts of version control systems (VCS) out there that people have been using with their PCB design software. As discussed in Why Use a Version Control System, we looked at different options ranging for local hard drive storage to sophisticated online revisioning systems. In this article we will be reviewing the differences between a standard VCS and Altium 365.

Recovering Copper Losses
Blog
Recover Conductor Losses By Clearing Your PCB Ground Layer

Controlled impedance routing at high frequencies is difficult enough, and it's important to make sure that you stay within your loss budget on long routes or in lossy media. When you have to route a long trace or a long differential pair to a connector or another component, what can you do if you're reaching the end of your loss budget? In this article, we’ll take a look at the skip reference routing method and explain how it can help recover some loss budget in a lossy interconnect.

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New in Altium Designer 25
Coming Soon: Export 3D-MID Tracks as Centerline Curves

Coming Soon: 3D-MID Track-to-Centerline Export allows you to export conductive tracks on 3D substrates as precise centerline curves within STEP files—enabling seamless integration with advanced 5-axis manufacturing processes. Explore more upcoming upgrades on our Coming Soon page.

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New in Altium Designer 25
Advanced xSignal and Impedance Control Techniques - Recording Preview

This webinar recording explores advanced xSignal and impedance control techniques in Altium Designer 25. It covers defining xSignals, managing impedance profiles, differential pairs, and delay tuning—all essential for high-speed PCB design. Full recording you find here: April 2025 COM Webinar Recording.

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How-To's
Coming Soon: Embedded 3D Models for Harness Designs

Coming soon: the Embedded 3D Models for Harness Designs feature will automatically include Parasolid-format 3D models in your harness layout drawings. This improves integration with MCAD CoDesigner, enabling seamless synchronization between electrical and mechanical design domains. To see more upcoming upgrades, visit our Coming Soon page.

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New in Altium Designer 25
Make Smarter Design Decisions with Signal Analyzer by Keysight

Discover how to simplify your workflow and boost design confidence with Signal Analyzer by Keysight—a complete extension available right inside Altium Designer 25. This whitepaper shows you how to analyze impedance, delay, and insertion/return loss without ever leaving your design environment.

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Altium Designer's 25 Quantitative Benefits
Unveiling 86% Task Time Efficiency in Altium Designer 25

Watch how Altium Designer 25 saves time on PCB visualization. This short video shows a side-by-side comparison of the same task done in Altium Designer 25 vs. an external CAD tool—revealing big time and click savings. A great teaser to highlight the value of the unified design environment and promote the Benefit Calculator.

Embedded thumbnail for AGND vs PGND: Proper Net Tie Connections in Power Regulator PCB Design
How-To's
AGND vs PGND: Proper Net Tie Connections in Power Regulator PCB Design

What’s the difference between AGND and PGND — and when should you use a net tie? Zach Peterson breaks down proper PCB layout for buck converters, grounding best practices, and why component placement matters in switching regulator designs.

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Altium Stories
Students at Monash UAS Fly Higher with Altium Solutions to Power Their Autonomous Drone Technology

Discover how the Monash Uncrewed Aerial Systems team leverages Altium Designer, MCAD CoDesigner, and Altium 365 to develop custom drone boards for critical humanitarian missions.

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New in Altium Designer 25
Say Goodbye to Disjointed Workflows: Unified Product Design in Altium Designer 25

Check an overview of how Altium Designer 25 unifies Multi-Board and Harness Design into a seamless, efficient workflow for faster, error-free product development.

Embedded thumbnail for From Concept to Reality: Updated 3D-MID Demo in Altium Designer 25
New in Altium Designer 25
From Concept to Reality: Updated 3D-MID Demo in Altium Designer 25

A walkthrough of the new 3D-MID capabilities in Altium Designer 25. Covers setting up a 3D PCB document, component placement on curved surfaces, routing with grids and sketches, exporting for LDS manufacturing, and generating a 3D pick-and-place file.

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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.

Embedded thumbnail for Design Smarter - Harness, Multi-board, and MCAD CoDesign in Action
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.

Embedded thumbnail for Unified Login in Altium Designer 25
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.

Embedded thumbnail for Custom Ethernet Switch Powers Up: Assembly to Working Hardware Test
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.

Embedded thumbnail for Mastering Pad and Via Templates (or Padstacks) in Altium Designer
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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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.