
PCB Prototyping Pitfalls: 5 Must-Check Details for Engineers to Avoid Wasting Time and Money
2025-09-22
1. Introduction: Have You Experienced the Pain of Prototyping Failures?
Many engineers spend a week on PCB design, only to have the prototype fail due to a small oversight during prototyping—like forgetting to mark silkscreen direction (causing reversed component soldering) or choosing the wrong board material (resulting in insufficient high-temperature resistance). PCB prototyping costs little, but repeated rework seriously delays project progress. Today, we’ll share 5 details to check before prototyping.
2. 5 Details to Check Before Prototyping
Detail 1: Silkscreen "Clear and Non-Overlapping" to Avoid Soldering Errors
Silkscreen guides soldering. Blurry, overlapping silkscreen or incorrect polarity markings (for diodes, capacitors) cause reversed component soldering and direct board failure.
Check Method: Enable the "3D View" in design software (e.g., Altium) to see if silkscreen covers pads or overlaps with other components. Focus on checking "±" or "PIN1" markings for polar components to ensure clarity.
Detail 2: Board Material "Matches Application Scenarios"—Don’t Blindly Choose Expensive Ones
Different scenarios require different PCB materials. For example, FR-4 works for ordinary consumer electronics, while FR-4 high-Tg (Tg ≥170℃) is needed for industrial high-temperature environments (temperature >85℃), and PTFE high-frequency materials for high-frequency communications (e.g., 5G). Choosing the wrong material causes PCB deformation or performance degradation in use.
Selection Advice: Use FR-4 (Tg 130-150℃) for general projects, FR-4 high-Tg (Tg ≥170℃) for industrial projects, and PTFE or Rogers materials for high-frequency projects. Clearly note the material model and parameters in the prototype order to avoid wrong deliveries.
Detail 3: Copper Thickness "Meets Current Requirements" to Avoid Board Burning
Copper thickness determines the PCB’s current-carrying capacity. Too-thin copper causes copper foil overheating and burning when high current passes through. For example, 1A current requires at least 1oz (35μm) copper, and 2A requires 2oz (70μm). Many beginners default to 1oz copper, ignoring current needs.
Calculation Method: Use the formula "Current Capacity (A) = Copper Thickness (oz) × Trace Width (mm) × 0.8". For example, a 1oz copper trace with 2mm width has a current capacity of ~1.6A. If current exceeds 2A, switch to 2oz copper or widen the trace.
Detail 4: Hole Size "Matches Component Pins" to Avoid Insertion Issues
Too-small through-holes or pin holes prevent component insertion; too-large holes cause cold soldering. For example, for a component with 0.8mm pins, the pin hole diameter should be ~1.0mm, and the through-hole diameter ~0.6mm (with a 1.2mm pad diameter).
Check Method: Refer to the component datasheet in the design software to confirm pin diameter. Make pin holes 0.2-0.3mm larger than the pin diameter, and through-holes 0.1-0.2mm larger. Avoid holes smaller than 0.3mm (difficult for manufacturers to process, prone to drill breakage).
Detail 5: "Panelized Design" Reserves "Process Edges" for Easy Production
Omitting process edges for panelized prototyping (multiple small PCBs combined) makes machine soldering impossible—only manual soldering is feasible, which is inefficient and error-prone.
Design Requirement: Reserve 5-10mm process edges around the panel. Add positioning holes (3mm diameter, no copper) on the edges for machine alignment. Connect PCBs in the panel with "V-CUT" or "mouse-bite holes" for easy separation later.
3. Conclusion: The "Final Step" Before Prototyping—Confirm with the Manufacturer
Before prototyping, send Gerber files to the manufacturer and ask their engineers to check for design issues (e.g., whether hole size, copper thickness, and material meet processing capabilities). Many manufacturers offer free DFM (Design for Manufacturability) checks, which effectively avoid rework. Remember: Spending 10 minutes checking before prototyping is better than 10 days of rework later.
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PCB Anti-Interference Design: From Theory to Practice, 3 Key Tips for Stable Signals
2025-09-22
1. Introduction: Why Does Your PCB Suffer From Interference?
When designing industrial control or high-frequency circuits, many engineers face this problem: the PCB works normally in the lab but experiences signal loss or data errors on-site. This is mostly due to inadequate "anti-interference design." Interference comes from sources like electromagnetic radiation, poor grounding, and power noise, but solutions follow a clear pattern. Today, we’ll share 3 practical anti-interference tips you can apply directly.
2. 3 Practical Anti-Interference Tips
Tip 1: "Single-Point Grounding" vs. "Multi-Point Grounding"—Choose the Right One
Grounding is the foundation of anti-interference, but many people confuse the application scenarios of these two methods. For example, using single-point grounding for high-frequency circuits (frequency >10MHz) leads to overly long ground wires, creating parasitic inductance that introduces interference. Using multi-point grounding for low-frequency circuits (frequency
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China Launches Anti-Dumping Investigation into U.S. Chips
2025-09-19
September 15 News – Recently, China’s Ministry of Commerce has initiated an anti-discrimination investigation into U.S. chip trade policies and a separate inquiry into dumping practices.
The first investigation will examine whether Washington has discriminated against Chinese companies in its chip trade policies. The second will focus on alleged dumping of certain U.S. analog chips used in devices such as hearing aids, Wi-Fi routers, and temperature sensors.
In a statement, the ministry noted that in recent years, the U.S. has imposed a series of restrictions on China regarding chips, including trade discrimination investigations and export controls.
It added that such "protectionist" practices are alleged to discriminate against China and aim to curb and suppress the development of high-tech industries in China, such as advanced computing chips and artificial intelligence.
A spokesperson for the Ministry of Commerce stated in response to media inquiries that the anti-dumping investigation was initiated upon the application of China’s domestic industry and complies with Chinese laws, regulations, and WTO rules. The investigation involves general-purpose interface and gate driver chips imported from the U.S.
The spokesperson mentioned that preliminary evidence submitted by the applicant shows that from 2022 to 2024, the volume of the investigated products imported from the U.S. increased by 37%, while the import price decreased by 52%. This has suppressed and driven down domestic product prices, causing harm to the production and operations of the domestic industry.
The spokesperson added that after receiving the application, the investigating authority reviewed it in accordance with the law and determined that it met the conditions for initiating an anti-dumping investigation. The authority will conduct the investigation in accordance with legal procedures, fully safeguard the rights of all interested parties, and make an objective and fair ruling based on the investigation results.
The spokesperson also stated that recently, the U.S. government has broadly defined national security concepts, abused export controls and "long-arm jurisdiction," and imposed malicious blockades and suppression on China’s chip products and artificial intelligence industry. These actions seriously violate WTO rules and undermine the legitimate rights and interests of Chinese companies, to which China firmly objects.
General-purpose interface chips are integrated circuit chips designed to provide diverse interface types for connecting various devices, systems, or components to achieve efficient data transmission and signal conversion. Gate driver chips are integrated circuit chips used to enhance the output of gate control signals from controllers and manage the switching on and off of power semiconductor devices.
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Source: Guoxin Network
Disclaimer: We respect originality and value sharing. The copyrights of texts and images belong to the original authors. The purpose of reposting is to share more information, and this does not imply our endorsement of the views. If there are any infringements, please contact us, and we will delete them as soon as possible. Thank you.
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Foxconn Mobilizes Nearly 200,000 Workers for iPhone 17 Production Rush
2025-09-19
On September 10, Beijing time, Apple officially unveiled four new models: the iPhone 17, iPhone Air, iPhone 17 Pro, and iPhone 17 Pro Max, with starting prices in China set at 5,999 yuan. Among the newly launched iPhone 17 Pro series, the orange, blue, and silver color variants are manufactured at Foxconn's Zhengzhou Port Area facility.
The Zhengzhou Port Area is currently in the mass production ramp-up phase for the iPhone 17 series. As production scales up, the demand for labor continues to grow. Reports indicate that "Foxconn has recruited more workers this year compared to last year." "In August, the referral bonus peaked at 9,800 yuan. During the high-demand period, tens of thousands of workers were hired daily, with the hiring surge lasting an entire week."
Temporary workers, particularly those referred through bonus programs, form a significant part of the workforce. These "referral bonus workers" receive an additional payout upon completing a specified employment period. Combined with their regular wages, they can typically save over 20,000 yuan within three months. In addition to these workers, Foxconn also employs hourly temporary workers.
During Apple's annual fall product launch cycle, the Zhengzhou Port Area factory enters its busiest period of the year. The demand for temporary workers spikes, driving referral bonuses higher. By late June, bonuses rose from 4,800 yuan to 5,000 yuan within three days. In late July, they exceeded 8,000 yuan, reaching a peak of 9,800 yuan in August before dipping to 7,300 yuan by month-end. In early September, bonuses quickly rebounded, surpassing 9,000 yuan and returning to high levels.
On the production floor, nearly 200,000 workers operate in two shifts, handling tasks such as screw fastening, film application, and component assembly. Conveyor belts continuously transport finished iPhone 17 units to the packaging workshop, where they are placed into white boxes bearing the Apple logo.
However, this workforce size is not the facility's historical peak. "At its highest, the facility employed up to 400,000 people. Apple was even more popular back then, and Foxconn was the primary manufacturer. Now, orders are more distributed, and Foxconn is no longer the sole producer," noted a source. Staff at the port area's human resources service center also confirmed, "Recently, thousands of workers have been entering daily—the volume is immense."
A long-term Foxconn employee with over a decade of experience mentioned that these temporary workers typically have contracts lasting only two to three months, aligning with the critical production ramp-up phase for Apple's new products. After this period, once production targets are met and order demand stabilizes, the facility gradually begins scaling down production lines.
A Foxconn Group HR manager stated that since August, overtime intensity has increased significantly. "Overtime work has surged dramatically, unlike last year's pace." Future production rhythms will depend on market conditions following the new product launch.
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Source: Guoxin Network
Disclaimer: We respect originality and value sharing. The copyrights of texts and images belong to the original authors. The purpose of reposting is to share more information, which does not imply endorsement of the views. If any infringement occurs, please contact us, and we will delete the content promptly. Thank you.
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Special Process Requirements in High-Frequency PCB Production
2025-08-22
High-frequency PCBs, such as those utilizing materials like TP1020, demand a set of specialized manufacturing processes to ensure optimal performance in applications operating at 10GHz and beyond. Unlike standard FR-4 based PCBs, these high-performance substrates require meticulous control over every production stage to maintain electrical integrity, dimensional stability, and material properties.
Material Handling & Preparation
The unique composition of high-frequency materials like TP1020—ceramic-filled polyphenylene oxide (PPO) resin without fiberglass reinforcement—necessitates specialized handling protocols. Prior to lamination, the raw material must be stored in a controlled environment with humidity levels below 30% and temperature maintained at 23±2°C. This prevents moisture absorption (critical given TP1020's 0.01% maximum absorption rate) which can cause dielectric constant variations exceeding ±0.2 at 10GHz.
Cutting and trimming operations require diamond-tipped tools rather than standard carbide blades. The absence of fiberglass reinforcement in TP1020 makes the material prone to chipping if subjected to excessive mechanical stress, potentially creating micro-fissures that degrade signal integrity. Laser cutting, while more expensive, is preferred for achieving the ±0.15mm dimensional tolerances required for 31mm x 31mm boards used in miniaturized antennas.
Lamination & Core Processing
High-frequency laminates demand precise lamination parameters to maintain dielectric consistency. For TP1020, the lamination process operates at 190±5°C with a pressure of 200±10 psi, significantly lower than the 300+ psi used for fiberglass-reinforced materials. This lower pressure prevents ceramic particle displacement within the PPO matrix, ensuring the targeted dielectric constant of 10.2 is maintained across the entire board surface.
The 4.0mm core thickness of TP1020 PCBs requires extended dwell times during lamination—typically 90 minutes compared to 45 minutes for standard substrates. This controlled heating cycle ensures complete resin flow without creating internal voids, which would act as signal reflection points at high frequencies. Post-lamination cooling must proceed at a rate of 2°C per minute to minimize thermal stress, critical for managing TP1020's CTE of 40ppm/°C (X/Y-axis).
Drilling & Plating Techniques
Drilling high-frequency PCBs presents unique challenges due to the abrasive nature of ceramic fillers in materials like TP1020. Standard twist drills wear prematurely, leading to hole wall roughness exceeding 5μm—unacceptable for high-frequency signal paths. Instead, diamond-coated drill bits with a 130° point angle are required to achieve the 0.6mm minimum hole size with wall roughness
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