Challenges Faced during PCB Designing


A Printed Circuit Board (PCB) is truly an important aspect of electronic items that are applied in practically all components in various fields, from little to enormous, from PCs, broadcast communications to military equipment. PCB assumes a huge part in executing elements of electronic items.

However, it’s never a simple errand to design a circuit board. Relationships, between layers, parts, or hardware, must be appropriately managed. Despite the difficult trait of PCB design, a few issues that regularly happen can be summed up so that PCB designers can get to know them ahead of time and figure out how to manage them before the PCB manufacture stage.

In this article, we are going to discuss the following;

  • Complexity in PCB design.
  • Common PCB design software.
  • What to consider when designing an ideal PCB.
  • General challenges in the PCB design process.
  • PCB Design Factors Affecting its Assembly.

Is designing Printed Circuit Boards Difficult?

Printed Circuit Boards’ design technology is constantly evolving with new complex designs moving into production. Thanks to the rapid advancement that has led to PCB designs that are powerful yet small in size. The demand for more modest and powerful gadgets has driven designers out of their comfort zone. Only skillful and clever PCB designers can comprehend the application needs of the Printed Circuit Board and propose changes or upgrades to the design of equipment.

PCB designing, Rewarding Career with Excellent Prospects

  • Printed circuit board designing is a difficult and comprehensive industry. However, today is quite possibly the most rewarding calling.
  • One of the new PCB design industry reviews shows that laborers in this industry are getting high salaries out of more significant compensations and rewards, expanded benefits and education opportunities, bigger staff numbers as well as better employer stability.
  • All in all, the possibilities, concerning PCB designing, are fantastic. In addition, rigid, flex, and rigid-flex printed circuit board producers all around the world are searching for youthful designers for an enormous scope.
  • The statistical analysis confirms that around 59% of Printed Circuit Board designers overall are beyond 50 years old, and with regards to the US, the numbers ascend to 66.5%.
  • Nearly half of PCB designers fall between age 51 and 55 while 18% are under 40. This implies that the business is maturing, and a bigger number of designers are close to the furthest limit of their profession.
  • More opportunities will therefore be available in the coming years in the PCB design industry. There are several opportunities for young and new designers around the world.

If you are fascinated with complex electronic circuits, then you belong in the PCB design industry.

What to consider when designing an ideal Printed Circuit Board

With regards to the manufacture of customized printed circuit boards, the 1st thought anybody considers is the different types of custom PCB designs to browse.

However, for a knowledgeable individual in the PCB creation and customization process, it is vital to recognize that it needs to be thought of factors and not the kinds of custom PCB designs.

The kinds of PCB designs like double-sided, single-sided, rigid, flexible, rigid-flex, HDI, and so forth are significant considerations.

The determination of the type of PCB design is essentially affected by a few elements. This section will acquaint you with significant elements that impact the determination and execution of types of custom PCB designs.

Challenges in the Selection of Custom Printed Circuit Board Designs

Regardless of the type of PCB being manufactured, certain challenges might force limitations on creation. The contemplation of the following elements will limit or avoid restrictions on the manufacture of various types of custom PCBs.

  1. Types of Interconnect:
  • The custom PCB plans are becoming minimal with progressions in technology. It requires the utilization of small spaces by placing components in a confined space without imperiling productivity.
  • In specific cases, generally, HDI (High-Density Interconnect) PCBs are taken on. This permits the packing of parts on a PCB for elite execution.
  • Notwithstanding, the interconnect construction might hinder design as interconnects may go through edges, drills, and so on which in the long run impacts the adaptability or part mounting in double-sided PCBs
  1. The Kinds of Vias:
  • Vias are the associations/connections between the parts. These metal lines associate the parts and communicate the signal starting with one part then onto the next.
  • In the customization of various types of PCBs, different vias types are taken on. For the board design types like single-sided or rigid PCBs, direct vias can be picked.
  • Nonetheless, these direct vias may present limitations for rigid-flex and HDI sorts of PCBs. In such cases, buried or vias- in-pad are picked. For high-density, high-frequency PCBs extraordinary types of vias are picked.
  1. Stack-up Parameters:
  • The layer stack-up is a significant element in choosing a PCB plan. Regularly for multi-facet boards, the drill design, number of layers, the material of the substrate, and so forth, sway the design boundaries of the PCBs. Hence, these elements should be selected cautiously.
  1. Drill Pattern:
  • It is the design of openings made to embed part leads. The drill example ought not to have any drills on the edges or twisting locales of the board.
  • On the off chance that the drill design is mind-boggling, the adaptability or format of vias might be limited which in the end impacts on types of custom circuit board designs.
  • Alongside these previously mentioned factors, a couple of more factors need to be thought to guarantee the exhibition and productivity of the chosen type of circuit board design.

Exceptional Considerations

Considering the accompanying elements helps in enhancing the nature of PCB creation.

  • Pick the plan that offers dependable and strong execution.
  • Select dependable PCB manufacture, assembly, and testing methods.
  • Decide on sans lead PCBs plan and advancement process assuming RoHS consistency is required or in any case.

Now that every one of the variables past the types of custom PCB plans is examined, it is suggested that you put resources into top-notch PCB creation companies from trusted dealers.

Printed Circuit Board (PCB) Design Factors Affecting its Assembly

The assembly process of PCB depends on the creation information of a PCB design and the specs of PCB manufacture. The great PCB configuration will work with ensuing PCB assembly handling, while the deficient design will influence the handling system and even influence the nature of the last PCB assembly item. So what are the PCB configuration factors that will influence PCB assembly handling/processing? Here are a few issues that PCB designers need to pay close attention to.

  1. The soldering position should have no silkscreen. This will influence the assembly quality by forestalling solderability.

Image: Wrong PCB design that silkscreen on SMT PAD

  • In any case, constantly the silkscreen sign of basic ICs is essential because it tends to be utilized to distinguish the deviation of solder quality (particularly for some high valuable QFN parts).
  • Therefore the IC’s edge imprint can be put at the edges of the SMT region to abstain from any covering issues to soldering PAD.

Image: IC edge marking to prevent silkscreen on SMT

  • The base distance between the copper foil and board edge is 0.5mm, the base distance between part and board edge is 5.0mm, and the base distance between the pads and board edge is 4.0mm.
  1. Important of Fiducial imprint and Tooling openings:
  • Fiducial imprint (red bolt in beneath picture) is important to be put in single PCB or board.
  • It is utilized on assembly machines as the reference position for a paste printing machine or a pick-and-spot machine to guarantee exact electronic parts patching activity in the PCB assembly process.
  • Normally the base distance across a roundabout fiducial imprint is 1.0 mm with a 3.0mm solder cover opening region.

  • cooling openings (pin bolt in the above picture) likewise is a non-plated opening, which is with typical size 3.0mm with the amount of 3pcs basically to be put on the circuit board. This is used to fix the Printed circuit board for not unreservedly development during PCB in the creative interaction, for example, electronic test cycle or blueprint profile process. These are fundamental openings for accommodation to the PCB creation and assembling process.
  1. While planning the twofold-sided board, focus on the parts of the metal shell. Whenever the shell is in touch with the printed board when DIP, the bind cushion on the top layer can’t be opened, and it should be covered with weld veil oil or silkscreen oil.
  1. Try not to put the jumper track under the IC, engines, potentiometers, or different parts with enormous metal shells.
  2. There should be no copper foil (aside from establishing required) and parts (or as expected by the primary drawing) inside 5mm of the screw opening span.
  3. Electrolytic capacitors would not touch be able to warm producing parts, like high-power resistors, thermistors, transformers, radiators. The base distance between electrolytic capacitors and radiators is 10 mm, and the span between different parts and radiators is 2.0 mm.
  1. Huge parts, (for example, transformers, electrolytic capacitors with a breadth of more than 15mm, attachments with enormous flows) should expand the cushion.
  1. The base track width/dispersing: 0.1mm/0.1mm; it will take an additional test to PCB creation ability and its assembling cost will raise in like manner if the track width/dividing under 0.1/0.1mm. Assuming that your last electronic item is a high coordinated circuit plan and has the restricted actual size to PCB board, you need to think about less track width/dispersing and the assembling cost is at a sensible reach.
  1. The cushion size (measurement) of the overall through-opening mounting part is two times the opening breadth. The base of the twofold-sided board is 1.5mm and the single-sided board is somewhere around 2.0mm. If round cushions are not accessible, midsection cushions can be utilized.
  1. In the event that the middle distance of the cushion is under 2.5mm, the encompassing cushion ought to be wrapped with silkscreen oil, and the width of the silkscreen oil is 0.2mm.
  1. For parts that should be fastened through the tin heater, the cushion ought to be opened away from the tin position. The heading of the cushion is inverse to that of the tin, which is 0.5mm to 1.0mm. This is predominantly utilized for the back-welded cushion in one side to abstain from hindering while passing the heater.
  1. In the huge region PCB plan (more than around 500cm or more), to forestall the PCB board from twisting while going through the tin heater, a 5mm to 10mm hole should be left in the center of the PCB board without parts (can be steered) to be utilized to add bowing bars to forestall bowing while going through the tin heater.
  1. To diminish short out-of-weld joints, all twofold-sided vias don’t open patch cover windows.
  1. Keep sufficient actual separating between SMD parts or through opening welding parts, or, in all likelihood stay away from any potential edge-covered issues, which will take the additional difficulty to SMD get together process (the deviation fastening issues).

Common PCB designing Software

The following are the absolute most well-known PCB designing software. You can find out about these PCB plan programming here.

  1. Eagle is one of the well-known and simplest PCB designing software. This software represents an Easily Applicable Graphical Layout Editor which has recently evolved by Cad Soft. For planning circuit graphs, EAGLE has a schematic proofreader. Eagles Board document extension is. BRD.
  1. Multisim is powerful and simple learning software that incorporates microcontroller simulations (MultiMCU) and coordinated import trade elements to the PCB design software. This product is generally utilized by scholars and in the industry for circuit instruction.
  1. EasyEDA is software that is utilized to plan and circuit simulations. It is an incorporated device for the schematic catch, SPICE circuit recreation, in view of Ngspice and PCB format.

The most significant benefit of this software is that it is an online design software and is utilized in the program window. Thus, it is independent of the operating system.

  1. Altium Designer is software is created by an Australian programming organization. The principal component of this software is the schematic catch, 3D PCB plan, FPGA advancement, and delivery/information to the executives. This is the first programming that offers 3D representation and freedom checking of PCB straightforwardly from PCB proofreader.
  2. Ki Cad is a creation of Jean-Pierre Charras. It has instruments that can make BoM (Bill of Material), work of art, and 3D perspective on PCB as well as all parts utilized in the circuit. A large number are accessible in the library of this software and there is include that client can add their custom parts. This product supports numerous human dialects.

Common PCB Design Problems

The most fundamental type of design for making as it applies to PCBs is the utilization of configuration rules and configuration rule checking in PCB design software.

Design rule checking (DRC) is the method involved with taking a look at a plan to check whether it adjusts to the assembling abilities of a PCB fabricator.

DRCs are generally coordinated with PCB design programming and are not commonly considered as extra services. Advanced designs for fabricating analysis software are additionally accessible to search for more complicated and more subtle design imperfections.

Regularly, DFM software checking is presented by PCB fabricators to clients as an additional service. The justification behind this differentiation is a direct result of the addition to the cost of very good quality DFM software and there is a need for more training on how to utilize it.

Let’s take a look at these common PCB design related problems;

  1. Starved thermals: This happen when thermal relief traces associated with a pad are not well connected with the copper plane.

The space between the vias will regularly pass a fundamental design rule check. however, the joined thermal relief traces will be hindered and those vias that will be affected improperly separated from their designated pours. This problem is normally seen when several vias are set too close to one another.

  1. Silvers:

Assuming tiny bits of a copper pour are simply connected to bigger bits of a similar copper pour through a limited or narrow trace, they are prone to break during manufacture, “float” to different parts of the board, and cause accidental shorts.

The issues introduced by silvers have been diminished lately by fabricators changing to the utilization of photo-actuated carving solutions. So while silvers are still to be kept away from in designs, they are not as overwhelming of an issue as they have been in the past.

  1. Acid Traps: In the joint of 2 traces, it’s however conceivable that an etching solution used to eliminate copper from the board will get held at the intersections. This trap is usually alluded to be an acid trip.
  1. Annular rings: Vias are always made by penetrating through pads by drilling one or the other side of a board followed by plating the walls of these openings to connect the different sides of the PC board.
  1. Via in Pad: Periodically it very well might be advantageous to design via to be situated inside a PCB pad. Notwithstanding, via in pads can cause problems during the assembly process. The solder will be drawn away from pads by Via causing the part that is connected together with the pad not appropriately mounted.

The picture beneath shows contrasts between via in-pad PCB and typical PCB.

  1. Copper being too near to the board’s edge:

Regularly discovered during the process of design rule checks, setting copper layers excessively near the periphery of a board can make those layers shot together when the board is cut to a close estimate during the manufacturing process.

Even though this kind of blunder ought to be found using DRC features, regularly accessible in PCB design automation software, a PCB manufacturer who does not use a DFM check can likewise get this challenge.

  1. Missing solder masks in pads:

In tight pacing in little pin pitch gadgets, it is very normal for the spacing to be with no solder cover between pins because of the standard design layout settings. The exclusion of the solder mask may prompt solder spans framing all the more effectively when the well pin-pitched part is joined to the PCB during the assembly process.

The picture underneath shows a highly exact solder cover between 0.40 pitch the QFN pads.

  1. Tombstoning:

Whenever little aloof surface mount parts are bound to the PCB assembly utilizing a reflow process, which is usual for them to lift toward one side and “tombstone”. Tombstoning can incredibly influence PCB outcomes and right away drive up creation costs. The wellspring of tombstoning may be wrong landing patterns and imbalanced heat relief to the stack of the gadget. Tombstoning may be successfully moderated by the utilization of the DFM checks.

Beneath the picture is the tombstoning test and its sketch of schematic.


Even though the area of PCB design is facing some challenges, quick solutions seem to be put in place to curb them. With the quickly evolving PCB technology, these challenges will be an issue in the past.