Understanding Common PCB Issues & Defects

Printed circuit boards (PCBs) are crucial elements in many modern electrical devices, linking various components via intricate circuits. The global demand for PCBs has surged over the past eight years, driven by efforts of several PCB makers online & local manufacturers to mitigate issues related to conflict minerals and advancements in technology.

Given the major investments in PCBs and their importance in various electrical devices and assembly processes, repairs of printed circuit boards have become a significant concern for many businesses. Understanding the common causes of PCB failure can help you better prevent and manage these issues effectively.

Understanding the PCB Failures

There are several reasons behind a PCB failure that leads to complete damage to the circuit board. With a vast application in electronics, such as industrial, aerospace, and domestic, thus making it important for any defect to be detected and fixed with immediate effect. Nominally the issues with PCBs can be prevented by keeping general knowledge of why it happens.

Slivers

These are tiny pieces of copper or solder masks that can detach during manufacturing, potentially causing short circuits or corrosion. They often arise from the etching process or overly narrow cuts in any single-layer PCB board design. To minimize sliver formation, adhere to design guidelines that specify minimum widths and employ DFM checks during the manufacturing process.

Missing Solder Mask Between Pads

The solder mask protects copper traces from unintended contact, but if it’s absent between pads, it can lead to solder bridges and short circuits. This defect often results from design oversights, highlighting the importance of thorough pre-manufacturing checks to ensure proper solder mask application.

Plating Voids

Plated through-holes are critical for electrical connections in any single-layer PCB board or 2-layer PCB board, formed by drilling and electroplating copper into the holes. However, the deposition process isn’t flawless. Plating voids can prevent current from flowing properly, leading to defects. These voids often arise from contamination, insufficient cleaning, or inadequate drilling techniques. To mitigate this risk, it is advised to ensure thorough cleaning post-drilling and adhere closely to manufacturer guidelines.

Insufficient Copper-to-Edge Clearance

Copper is highly conductive but also prone to corrosion. When PCBs are trimmed, if the copper is too close to the edge, it may be exposed, leading to potential short circuits and environmental damage. Maintaining proper copper-to-edge clearance is very crucial, and a comprehensive Design for Manufacturability (DFM) check can help identify and rectify this issue before production.

Bad Soldering

Soldering is a delicate process, and poor techniques can result in cold solder joints or contamination that compromises the circuit in any single-layer PCB board. Issues can be detected through visual inspections or X-rays, but it’s vital to follow best practices during soldering to ensure the integrity of the connections.

Acid Traps

These problems are created by acute angles in circuit designs that can hold etching acid longer than intended, leading to over-etching and defective connections. Designers should avoid sharp angles and verify their layouts to prevent this issue, which can be caught during DFM reviews.

Poorly Manufactured Components

The use of substandard components can lead to connection failures and power issues in several different single-layer PCB boards & 2-layer PCB boards. Ensuring high-quality components are sourced and inspected can prevent these costly problems.

Starved Thermals

Thermals help dissipate heat, but if connections are poorly made, they may not perform effectively, leading to overheating. Issues with thermals usually stem from manufacturing flaws, so it’s essential to select experienced manufacturers who can spot and rectify these issues.

Electromagnetic Issues

Electromagnetic interference (EMI) can significantly impact PCB performance. To combat this, design strategies such as increasing ground areas and avoiding sharp angles can help minimize EMI effects.

Environmental Factors

Exposure to moisture, dust, and extreme temperatures can deteriorate PCBs over time. Proper environmental controls during manufacturing and storage are essential for maintaining PCB integrity.

Lack of a DFM Check

A comprehensive DFM check is crucial for identifying design flaws before production. Many issues can be prevented with a careful review, helping to avoid costly scrapped boards and redesigns.

Burned Circuit Boards

High temperatures during manufacturing can damage closely packed components. Ensuring adequate spacing between components can help prevent overheating and potential failures.

Summary

Navigating the complexities of PCB manufacturing requires attention to detail and proactive measures. By understanding these common issues and implementing best practices, manufacturers can significantly enhance the reliability and longevity of their circuit boards. A strong emphasis on DFM checks and quality control processes not only helps in catching potential problems early but also ensures that the final products perform reliably in the field.

CircuitWala’s skilled engineering team takes a meticulous approach to PCB manufacturing. We conduct thorough DFM checks on design files and test runs, storing the results in our advanced custom ERP system to keep our clients informed. Whether you need help with circuit board troubleshooting or other aspects, we’re here to assist you as your one-stop PCB makers online. Our PCB diagnostics techniques can pinpoint necessary design modifications, ensuring you receive feedback on preventing delays and quality issues before they arise.

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