Printed Circuit Boards (PCBs) are the primary functional center for most electronics, replacing the old point-to-point wiring systems. PCBs use copper planes for grounding and powering circuits, providing many benefits, including shorter paths, improved circuit decoupling, and increased current carrying capacity.
Have you ever noticed that most of the technology and electronics we use today would not be possible without the use of Printed Circuit Boards (PCBs)? Whether it’s a medical device that monitors vitals or a smartphone, all these devices contain PCBs at the core of their heart. PCBs help decrease the size of electronic products, making them cost-effective as well. Over time, PCB manufacturers have also improved to keep up with the increased demand for the latest, faster, and more complex electronic circuitry. With the growing use of applications such as robotics, the Internet of Things, and artificial intelligence in our daily lives, the demand for electronic devices has also increased. Indicating that the future of PCBs is very bright and that the Printed Circuit Board technology will continue to strengthen in the future.
In fact, according to Future Market Insight report, the global PCB design market was valued at around US$ 3 bn in 2022, registering a growth of 12.7%. By 2029, the market is expected to grow at a CAGR of 14.9% and reach US$ 7.92 bn in valuation.
Before the advent of PCBs, circuits were constructed using point-to-point wiring, which was laborious and difficult. PCBs are sometimes referred to by other names, such as “printed wiring boards” or “printed wiring cards”. Wire junctions and short circuits often failed due to wire insulation aging and cracking.
A breakthrough came with the development of wire wrapping, which creates an extremely durable and easy-to-change gas-tight connection by wrapping small gauge wire around posts. It was only due to this innovation that electronic components became smaller and less expensive as vacuum tubes and relays were replaced by silicon and integrated circuits. As electronic products became more prevalent in consumer goods, manufacturers sought better solutions to reduce their size and manufacturing costs. Thus, the PCB emerged.
To avoid failed PCB designs, it’s important to use a consistent polygon and grid system. While it may be tempting to work with multiple grids or polygon shapes, doing so can increase complexity and cause polygon-fill issues. By adhering to spacing guidelines and keeping trace lengths short and direct, you can prevent issues such as shorts, Electromagnetic Interference (EMI), heat dissipation, and ground faults. It’s also important to keep your components grouped on your grid and avoid 90° bends in traces, which can easily result in shorts. Instead, stick to direct and short routes and opt for gentle 45° turns in traces. Keeping loops small will also reduce inductance and HF voltage spikes.
When it comes to PCB design, silk screening is a crucial factor to consider, despite not being directly related to the board’s function. Properly implementing silkscreening can enhance the manufacturing, testing, servicing, and overall usability of the board. Even if the annotations on the silkscreen layer are hidden under components, they still serve their purpose. In fact, going through the process of labeling on the silkscreen layer may even reveal design flaws that were previously overlooked. Using silkscreen on both sides of the board can help streamline the production process and improve the overall quality of life for both the designer and the end user. Essentially, silk screening is a quality-of-life decision that can benefit everyone involved in the board’s lifecycle.
To effectively power and ground a PCB design, copper planes connected to the power and ground connections respectively, are crucial. These planes, known as power planes and ground planes, provide many benefits for the overall design. However, it’s important to note that only PCBs with four or more layers can accommodate power planes.
The use of power planes can yield significant returns on your investment, including shorter paths, improved circuit decoupling, and increased current carrying capacity. By contrast, traces have limited current carrying and heat capacity, meaning that heat will build up more quickly and result in greater resistance in a smaller area. Power planes also help to lower temperatures, reduce wasted electricity, and improve overall function.
Another convenient feature of power planes is their ability to act as decoupling capacitors when vias are used to connect them to the signal layer. This helps to reduce unwanted noise and interference from propagating throughout the PCB design. Overall, the use of power and ground planes can greatly enhance the performance and reliability of a PCB design.
When it comes to PCB design, the software you use can play a crucial role in the success of your project. While free versions of software may be available for beginners, industry-standard software is necessary for professional work. Some of the top PCB design software used by professionals include Altium Designer, Solidworks PCB, and Autodesk Eagle. While these are not the only options available, they are widely used in the PCB design field. Additionally, Autodesk Eagle offers free licensing for personal use.
Regardless of which software you choose, it’s important to ensure that it has the capability to generate all the necessary PCB layout files, including Gerber files or ODB++. Other essential files include Centroid or “Pick and Place”, Bill of Materials (BOM), special requirements (ReadMe text or PDF), and Assembly Drawings (PDF filetype). These files are typically the minimum requirement, but additional files may be needed depending on the product and client specifications. Ultimately, choosing the right software is crucial for creating a successful PCB design project.
Today, electronic components are connected through circuits on a PCB, which serves as the primary functional center for most electronics. PCBs are used across a wide range of industries, and new applications are being discovered every day. With a variety of configurations and types available, PCBs offer flexibility and can be used in various applications and capacities.
Let’s explore these applications in more detail.
A wide variety of electronic devices are used in the healthcare industry for diagnosis, monitoring, and treatment. The medical applications of electronic devices continue to expand as technology becomes more efficient and denser.
A PCB is at the heart of all these medical devices. Due to the unique constraints of medical devices, PCBs used in the medical industry require a specialized design. An emergency room monitor or surgical implant typically requires a small package, which is why medical PCBs tend to be high-density interconnect PCBs, commonly known as HDI PCBs. There is a wide variety of flexible base materials that can be used in medical PCBs. The health implications of medical PCBs make them subject to higher standards, and medical PCB suppliers must adhere to stringent medical regulations while achieving repeatability and reliability.
Common Medical Printed Circuit Board Applications:
Smartphones and computers, for instance, are consumer electronic devices. Even new refrigerator models include electronic components.
The number of PCBs manufactured to control these consumer electronics must be equal due to their high-volume manufacture. Since these high-volume PCBs have a low per-unit cost, they keep the final product at an affordable price. The PCB industry must adhere to strict quality control and industry standards like IPC to guarantee the quality and uniformity of every consumer electronic. PCBs are extensively used in consumer electronics. Here are a few common applications:
PCB’s high-power industrial applications are also common. These electronic components are used to control machinery in factories and manufacturing facilities, and they must withstand harsh conditions. Any type of hazardous chemical, vibrating machinery, or rough handling can be included in this.
Industry standards must be rigorous in such a fast-paced, challenging environment. There are several other applications for thick copper PCBs (significantly thicker than standard-ounce PCBs) now. Such PCBs are suitable for battery chargers and high-current industrial applications.
Today’s automobiles incorporate many new applications in PCBs to take advantage of advancing electronic circuit technology. Most sensor applications in cars use high-frequency PCBs, such as RF, microwave, or millimeter-wave, to detect blind spots, maintain traffic conditions, and avoid collisions using radar technology.
Advanced driving systems are becoming more popular in vehicles as they enhance safety and the driving experience. Consequently, the manufacturers of these systems must source and use a higher volume of high frequency printed circuit boards.
PCBs are commonly used in automobiles for the following purposes:
In aerospace applications, PCBs are required to be precise and durable, just as they are in automotive applications. A rigid PCB may endure enough stress to become damaged during a jet or rocket’s atmospheric journey due to the high level of turbulence that the jet or rocket experiences. This is why most aerospace manufacturers use flexible PCBs, which are light, compact, and vibration resistant.
Besides being exceptionally durable, aerospace PCBs need to be extremely precise and high-functioning and manufactured for optimal functionality to prevent technical problems. Aerospace technology electronics must perform perfectly since they play a crucial role in the safety of vehicles and their crews.
The aerospace industry uses PCBs in a variety of applications, such as:
The printed circuit board provides a versatile platform for high-efficiency LED applications. The low-power consumption, high efficiency, and impressive light output of LED lighting solutions are putting them at the top of the list among a variety of industries. This LED’s versatility is further enhanced when it’s integrated with a PCB. PCBs permit LED lighting solutions to be applied to displays and indicators.
The lighting industry uses PCB LEDs for a variety of purposes, including:
Wherever electronics are used in the modern world, PCBs of all kinds will find applications. As broad and diverse as the market itself, PCBs have a wide range of applications.
eInfochips has also helped its clients who wanted to re-engineer their existing power meter system. eInfochips assumed full responsibility for the product redesign and development, leveraging Arrow’s market knowledge and supply chain to extend the life cycle by five years. To continue reading about the case study, click here.
Between 2022 and 2030, the PCB market is expected to grow by more than 5%. It reached $75 billion in 2021. Printed Circuit Boards (PCBs) have evolved significantly since their invention in the early 20th century. In the year 2023, several trends are defining the future of PCB design. PCB design is at the center of all electronic devices and technologies, including smartphones, medical equipment, and more. Let’s jump in.
To help you with taking decisions during the design phase of the PCB, material type, layout complexity, and prediction challenges, which can impact the pricing of the product and the time to market, you can read more about the blog here.
As far as product functionality and device capabilities are concerned, the PCB industry has a bright future. The PCB manufacturing industry must continue to evolve its processes, techniques, and equipment to achieve these aspirations. Our end-to-end product design engineering services, which we offer through eInfochips, have led to the design and development of 500+ products. In addition to offering the best-in-class hardware design engineering services to clients in a variety of industries, eInfochips has a strong ecosystem of partners. To know more about our key offerings and services, contact our team of experts today.
