All posts by Dl Design

How you can reduce your PCB manufacturing costs

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1. Smarter design
Planning the PCB layout and assembly process is one of the most smart and cost effective ways of saving money.
The strategical engineering of these boards can result in using fewer and more cost effective parts which will significantly lower the cost of each PCB.

In the long run, this will enable your company to reduce costs and deliver high quality PCB layouts.

 

2. Use manufacturers reference designs
Engineers designs can look good on paper but when it comes to design, costs could impact on overall cost and reduce profit. Costs can increase during the manufacturing stage.
One of the cost effective ways is to refer to manufacturers notes. The information provided can save effort, time and money for the design to be produced.
A decent chip manufacturer will provide a schematic, BOM, gerber and assembly drawings and reference designs.
The reference designs are created by the manufacturer to show how the design is made to their specification.

 

3. Panelise
Placing multiple PCBs on the same panel allows all of them to processed at the same time, instead of separately. Not only are boards manufactured like this, they are assembled and shipped on a single panel. The more PCBs on one panel, the more cost effective it becomes.

 

4. Get the Manufactures involved
Providing the manufacturers with any information during the design process can pay dividends when it comes to releasing the production files.

Board stack up, clearance issues, materials and special requirements – these could cause problems for the manufacturer and these could be costly if told in the last-minute.
By communicating and agreeing with in advance this would give the manufacturer time to resolve any issues and even offer an alternative solution.

You could have time to find an alternate manufacturer if your demands are not met.

 

5. Using the same assembly house for prototyping and mass production
Once the boards have been designed and manufactured, the assembly process can begin.
If there are no design changes between prototyping and productions it would be practical to use the same assembler for both and to start mass production as soon as possible.

Material costs are fairly low, significantly lower when bought in bulk. The main costs are time spent assembling the PCB.
It takes time to review the design and resolve any potential problems.

It takes even more time to add the parts into the pick and place machine. And it takes time for the assemblers to learn what’s required for the project. If this is achieved during the prototype, the mass production run will go much faster.

6 Common PCB mistakes

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1. Lack of planning

With PCB layouts, preparation is the most important part of the job.  The amount of time spent preparing will affect the success of the design.  Selecting the right PCB design software is the most important; each having advantages, disadvantages and limitations.

Each PCB is unique it it’s own way.

Some areas of the design are more important than the rest, for example power supplies, impedance signals, DDR, address and data bus.  If these areas are not completed before the rest of design, precious time is lost and considerable effort is then spent reworking the layout.

Setting up rules and constraints are there to guide from the placement stage till the gerbers are completed.  When a PCB is planned correctly, the rest of the design will become a much simpler process.

 

2. Constraint rules

There isn’t anything more powerful than the human mind, unfortunately it is not perfect!

There are lots of things to think about with a PCB design, and it is easy to get lost with all of the information.  By using the tools available from PCB software, constraints can be implemented; spacing, keepouts, length matching, propagation delays.

Once these rules have been implemented, the designer can focus on other areas of the layout.

 

3. Poor Communication

As PCBs become more complex, the communication between engineer and PCB designer is essential.  By eliminating any placement or routing issues early on can save on costly reworks.

It is very important for the engineer to review the circuit board as often as possible.  Using on-line meeting tools can allow the engineer to inspect the board in real time and discuss potential issues.

By setting out clear objectives and agreeing on them from the start of the layout can give the designer a better understanding of what you want to achieve and can shorten time-to-market.

 

4. Using ineffective layout techniques

PCB layouts are becoming more complex thanks to advancements in electronic technology.  Problems such as electrical noise, crosstalk, impedance mismatch, timing issues, ESD – all need careful consideration.
Practical PCB design rules, board stackup, PWR & GND planes, decoupling capacitors, faraday shields – these are valuable when used correctly.
Reference designs provides the optimum solution to meet requirements for complex layouts.  Some of their suggestion may be difficult to achieve, but they do give some insight on how the PCB should be designed correctly.

 

5. Forgetting to backup data

Backup completed designs, no brainer.  Hundreds of hours are invested in most designs, eventually all designs will have to be modified.

Obsolete components and new technology will demand the board is updated.

If the original files have been lost, the whole project will have to start again or be scrapped.  The use of a cloud is a cheap and easy solution to backing up data.

 

6. Becoming a One man island

Any experienced PCB designer may look on a completed design and see perfection.  It is easy to get “tunnel vision”; concentrating on one area of the board and missing a detail on another.  A colleague not as involved in the project can be more impartial and provide an objective and invaluable insight.

Regular design reviews can help detect future errors and allow individuals to share experiences and knowledge.

10 best practices of PCB design

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Despite increasing levels of semiconductor integration and readily available systems-on-chips for many applications, in addition to the increasing availability of highly-featured development boards, electronics often still require a custom PCB. Even for “one-off” developments, the humble PCB still performs an important role. It’s a physical platform for a design, and the most flexible for pulling an electronics system together. In this article, we outline ten best practices of PCB design, most of which have stayed consistent for 25 years. These rules are in no particular order, can generally be applied to any PCB design project, and should prove as a useful guide both to veteran design engineers as well as makers alike…

1. Use the right grid
Find a grid spacing that suits as many of your components as possible and use it throughout. Although multiple grids may seem appealing, a little additional thought at the early stages of the layout can avoid spacing difficulties and will maximize board use. Many devices are available in different package sizes, so use that to your advantage. Furthermore, as the polygon is an important shape when adding copper to your board, and boards with multiple grids will often produce polygon-fill discrepancies, not standardizing on one grid can make your life tougher than necessary.

2. Keep trace lengths as short and direct as possible
This rule applies even if it means going back over parts of the layout again to optimize track lengths. This applies particularly in analogue and high-speed digital circuitry where impedance and parasitic effects will always play a part in limiting your system performance.

3. Whenever possible, use a power plane to manage the distribution of power lines and ground.
Using pours on the power plane is a quick and easy option in most PCB design software. It applies plenty of copper to common connections and helps ensure power flows as effectively as possible with minimal impedance or voltage drop, and that ground return paths are adequate. If possible, run multiple supply lines in the same area of the board and remember that if the ground plane is run over a large section of one layer, it can have a positive impact on cross-talk between lines running above it on an adjacent layer.

4. Group related components and test points together
Place the discrete components needed for an opamp close to that device so the bypass capacitors and resistors are co-located with it. This helps with the track lengths in Rule #2, and it also makes testing and fault-finding easier.

5. Panelise your PCB by replicating the board you need several times on a larger board
Using a size which best suits the equipment used by your manufacturer will improve the cost of prototypes and manufacturing. Start by laying out the board as one panel. Ask your board house what size panel they prefer. Then, after your design rules have been corrected, do your best to step and repeat your design multiple times within the preferred panel size.

6. Consolidate your component values
As a designer, you will have picked some discrete components that could be a higher or lower value and work just the same. Consolidating on a smaller range of standard values makes the BOM simpler and probably less expensive. It also makes stock decisions easier in the long run if you have a range of PCBs based on your preferred device values.

7. Design rule check (DRC) as often as you can
The DRC function on PCB software takes a little time, but checking as you go can save hours on more complex designs, and it is a good habit to adopt. Every layout decision is important, but the DRC keeps the most important ones top-of-mind.

8. Use the silkscreen wisely
The silkscreen can be used to portray a wealth of useful information to the board builder, as well as the service or test engineer, installer, or device operator. Clear labels depicting functions and test points are obvious, but orientation of components and connectors should also be considered wherever possible. Even if annotation ends up under your components following board assembly, it’s still a good practice. Full use of silk screening on both sides of the board streamlines production and can reduce re-work.

9. Decoupling caps are not optional
Do not try and optimize your design by avoiding decoupling power lines and trusting the absolute limits of component data sheets. Capacitors are inexpensive and robust; take the time to fit them in wherever possible and remember Rule #6 – use a range of standard values to keep the inventory neat.

10. Generate your own PCB manufacturing data and verify it before sending it out to be fabricated
Most board houses will be happy to do this for you, but if you output your own Gerber files first and use a free viewer to verify it looks as you envisioned, then you can avoid misunderstanding. You may even catch an error inadvertently included before it’s set forever in fiberglass, resin, and copper.

As circuit designs are more widely shared, and reference designs are relied upon more and more by in-house teams, we believe it’s important that basic rules like these remain in printed circuit design. Keeping sight of the basics means developers retain the flexibility to add value to their products and extract the most from every board they make. Finally, anyone new to board design will accelerate their learning-curve and confidence when the basics are “designed in.”

Advanced Technology

 

 

Our design tools offer extensive support for advanced technology and high speed board design, with constraints (design rules) that allow tight control of critical sections of your layout. We also offer pre- and post-layout simulation for complete peace of mind.

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stackup: meeting your electrical performance requirements starts with the stackup, and we will work with you and your preferred board fabricator to ensure that critical impedance requirements are met.

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spacing: default (manufacturing minimum) spacing rules may be specified between all design elements (traces, vias, surface mount and through-hole pads, copper pours, holes); these may be overridden as required for nets, differential pairs, busses and net classes

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same net spacing: length matching and tuning can result in “serpentine” routing where extra length is added to a trace; in these cases, signal integrity concerns may require that the looping patterns within the same net are subject to a specific minimum spacing – typically this is 2x to 4x the vertical distance from the layer to an adjacent reference (ground or power) plane

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physical: physical characteristics can be specified for individual nets, differential pairs, busses and net classes – including nominal width, neck width and maximum length, spacing (for differential pairs) and allowed via types.

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differential pairs: pairs of nets can be treated as a differential pair, with a specified nominal width and spacing, and control of phase tolerance (maximum delta between the lengths of the pair) and the maximum length of uncoupled sections (typically at the source or destination)

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busses: groups of nets can be named and visualised as a bus during design planning

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net classes: nets can be grouped in “classes” and these can be used in turn to apply special spacing criteria between classes that take precedence – for example between differing clock domains

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absolute propagation delay: trace lengths can be constrained to stay within a specified minimum and maximum limits.

relative propagation delay: trace lengths can be constrained with respect to a target trace – for example data with respect to DQS in the case of DDR memory busses;

ddr_lane_relative_delay

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scheduling: the connection sequence of critical nets can be specified explicity – for example the address/command/control signals of a DDR3 memory interface can be forced to flow from the controller to the near end and then the far end of the memory devices.

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stubs: typically used in combination with scheduling, stub lengths can be constrained as required to meet signal integrity requirements

constraint regions: specific areas can be specified within which different physical and spacing constraints may be applied, for example in the escape region of a BGA

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Testimonials

Siemens
Amstrad
Grid Defence
Perkin Elmer
CodaOctopus
Transition Networks
BAE Systems
Tom Tom
Motorola
North Atlantic Industries
Vocality International
Omnivision
Nokia
BBC Broadcasting
Ultra Electronics
Oxford Instruments
Aerospace Logistics Ltd.
PPR Optoelectronics
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“I have worked with DL Designs since 1990, and have relied on them to deliver dozens and dozens of complex multilayer and high speed designs – always against very tight deadlines; I am talking about projects that mix 10G Ethernet, PCI Express Gen3, DDR3 and precision data converters.
The experience and can-do that this team brings to bear on my projects is unbeatable, I cannot recommend them highly enough.”
Technical Director, Ultra Electronics

“We use DL Designs as they are offer a highly experienced and responsive service which suits our needs.
DL Designs knowledge and technical ability are one of the key reasons we use their services. They consistently help us and complement our internal skill set to give us the ability to offer our customers a complete from design to manufacture service.
We need a fast and quick response for many of our products, DL Designs help us meet these deadlines.
DL Designs highly skilled team offer a great service for our complex boards at the right price.
We have recommended DL Designs already to a few companies we have worked with and would do again.”
Senior Design Engineer, PRP

“We have used DL Designs services for the last three years and DL Designs is a perfect partner for our company.
DL Designs provides us with an excellent layout service and helped our business to bring our products quick on the market.
One thing I liked was their flexibility in terms of a short time scales from our site for starting a PCB layout.
What we appreciated most about working with DL Designs was their ability to keep the budget and the time scale.
We would recommend DL Designs for their professionalism.”
R&D Team Leader, Siemens

“I was under extreme time pressure to materialise my schematic designs when my colleagues recommended DL Designs to me two years ago. I have been using DL Designs since and have always been impressed by the quality and consistency in the work they deliver.
DL Designs knows the art of PCB drawing. From the creation of footprints, component placement, impedance matching, layer stack up and design for manufacturing.
They have taken care of it all so that I don’t have to.
DL Designs have always helped us deliver on time and on budget. How they managed to pull that off despite multiple last minute requests from us is still a mystery to me.
I would highly recommend DL Designs to anyone searching for professional PCB expertise and hope my competitors will never hear about them!”
Senior Engineer, Siemens

“As an electronics designer I have used DL Designs over many years on numerous projects and have always found them to be an excellent partner.
DL Designs have provided me with a high level of technical expertise and experience that directly contributes to the success of designs.
When presented with difficult time scales they always put in the extra effort to deliver on time.
I would highly recommend DL Designs as a cost effective PCB design service that can be relied upon.”
Senior Electronics Engineer, Perkin Elmer

We estimate that DL-Design has improved our efficiency in PCB design layout over the original in-house developments by approximately 50%. As a result we have achieved the development targets with reduced costs and a reduction in potential layout issues.

Their support team are client friendly , always professional. They are a great asset to our business.
Chief Engineer, Transition Networks EMEA Ltd.

We use DL Designs for all our PCB Layout needs, ranging from simple, single sided, single layer boards to complex, high density, 10-layer boards with high speed, length matched differential pairs and they have never failed to impress.
DL Designs are highly skilled, flexible, easy to get on with and have a very structured and efficient way of working and communicating with their customers. I cannot think of a single board that has had an issue due to their wrong doing which is remarkable.
Placements and layouts are always neat and completed in a timely manner. We are a long term customer with our relationship extending back for over 8 years. Highly recommended, we wouldn’t use anybody else.
Electronics Design Engineer, GRID Defence Systems

Product Development

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Our core skills of PCB Design are complimented by Electronic, Firmware and Software design with experience and expertise in designing and delivering complete products and solutions. Together with our proven partners we offer you a full Product Development service from concept to production:-

Product Design
Feasibility & Concepts
Industrial Design
Electronics & PCB Design
Firmware & Software Design
Design for Test & Manufacture
Manufacturing; UK & Offshore
Production Test Solutions
Approvals & Compliance

Electronics
Digital, Analogue, Mixed Signal
Low Power Design
Microprocessor Solutions
PSU, Battery Management
FPGA, CPLD Design, VHDL
Wireless; Bluetooth, Wi-Fi, GSM
Signal Processing
Design for EMC Compliance

Technologies
Mobile Products
Internet of Things; M2M
Life Sciences
Telematics, GPS, Tracking
Wireless Power Transfer
Sensors & Monitoring
Test Systems
Comms; Wired, Wireless

Software
Real Time Embedded
C, Assembler
Small Footprint RTOS
ARM, Ti, Renesas, PIC
IDE; ARM, IAR, Keil, GCC, ImageCraft
OS; Windows, Linux
C#, MS Visual Studio
Production Test

The PCB Experts

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Commitment to your deadlines
DL-Designs has built a strong reputation for customer flexibility and total compliance to their requirements, we are able to adapt our approach when additional support is required for completing complex projects. Our expert team use the latest software which enables faster turnaround times, reducing time-to-market, and helping to maintain your competitive edge.
Deadlines can be achieved no matter how aggressive.

Quality:
Our quality control process ensures that design requirements are documented before any work is started. All completed designs undergo a thorough internal review and audit to ensure all design requirements and best practices are met.
Our commitment to customers is to ensure the design is right first time. This ensures all your projects are completed on time with less PCB modifications and greater production yields.

Highly skilled design team
Our team are experts in complex PCB designs. We focus on hand routing for efficient, cost effective circuit boards. The team has considerable experience and knowledge which puts DL Designs at the forefront of PCB design. Our familiarity and experience with the latest design techniques provides an extensive knowledge base from which you will benefit.

Complete solution
We can provide a complete service from initial concept through design to manufacture and test, providing a “one-stop shop”. This allows clients who want to maximise the benefits of out-sourcing.

Design Team on site
Design resource can be dedicated to clients premises if required for closer liaison with Design engineers.

Signal Integrity
We have completed many high speed designs, which has avoided the need for expensive signal integrity analysis costs. This is achieved by studying the product data sheets and reference layouts prior to design implementation.
SI analysis is available.

ISO9001:2008
DL-Designs demands the active participation and co-operation of it’s staff at all levels to maintain measurable, accountable, quality assurance and as a minimum, the requirements of ISO 9001:2008