The Key to First-pass Success in PCB Design

In the dynamic world of PCB manufacturing, achieving first-pass success hinges on more than just cutting-edge equipment and skilled teams. At Summit Interconnect, we have seen countless successful launches of advanced HDI designs that can be traced directly to engagement between designers and fabricators early in the design phase.

Unfortunately, collaboration in the PCB industry often begins only after problems arise—such as field failures, assembly fallout, or low fabrication yields. This reactive approach is the wrong starting point for collaboration.

When issues surface late in the design cycle or during production, the costs of fixing them escalate exponentially. Redesigns, delays, and rework add unnecessary complexity and expense, while product reliability and time-to-market suffer. To avoid these challenges, collaboration needs to occur earlier in the design cycle, where issues can be proactively addressed.

Bridging the Knowledge Gap

PCB designers often focus on functionality, performance, and compliance with end-use requirements. Meanwhile, fabricators look at manufacturability, process efficiency, and cost optimization. Proactive collaboration between the OEM and the manufacturer ensures that requirements and capabilities are aligned from the outset, minimizing potential conflicts between design intent and fabrication results.

Avoiding Costly Redesigns

Redesigns can be one of the most expensive and time-consuming hurdles in PCB manufacturing. Issues such as improper pad and drill size, drill-to-copper violations, incompatible materials, or unbalanced stackup requirements often surface during fabrication. When these problems are brought to a designer’s attention, the typical first reaction is to push forward as is or to make only minor, quick changes in the hopes that the manufacturing issues will go away. This approach is often prompted by budget constraints and looming deadlines, leaving little room to fully address root causes.

This reactive cycle has far-reaching consequences. Rushed redesigns may lead to:

• Compromised product performance
• Reduced field reliability
• Damaged reputations for both the designer and the fabricator
• Increased financial costs from wasted materials and delayed schedules
• Missed market opportunities, eroding a company’s competitive advantage

To break free from this cycle, we must shift the focus from simply “fixing the problem” to preventing it altogether through early collaboration. This proactive mindset creates opportunities to design for manufacturability (DFM) from the outset, leveraging the fabricator’s expertise to identify potential risks before they become roadblocks.

By working together, designers and fabricators can optimize key parameters such as layer count…

By working together, designers and fabricators can optimize key parameters such as layer count, via configurations, material choices, and tolerances. These optimizations lead to higher yields, particularly for first-pass production, which saves time and reduces overall manufacturing costs.

Enhanced DFM

Fabricators’ advanced CAM (computer-aided manufacturing) DFM tools provide valuable input on design rules and constraints specific to their processes, such as minimum trace widths, spacing, and drill sizes. These tools have evolved significantly, offering powerful simulations that go beyond basic checks.

For example, modern DFM tools can now simulate microvia reliability and predict potential bow-and-twist issues during fabrication, allowing designers to identify problematic designs before the layout begins.

Some key advantages of leveraging advanced CAM DFM tools include:

• Preventing wasted resources by detecting bow-and-twist issues before layout
• Ensuring microvia reliability through simulation, reducing the risk of field failures
• Enhancing long-term product reliability and customer satisfaction
• Streamlining the development process by eliminating back-and-forth design iterations
• Accelerating time-to-market and freeing up engineering resources for innovation

The cost benefits extend beyond direct manufacturing expenses. Reliable first-pass yields minimize wasted materials, reduce production delays, and prevent the cascading effects of redesigns on other projects. This proactive approach ensures designs are optimized for manufacturability, ultimately delivering better products faster and at a lower total cost.

Collaboration in Action: Real-world Example

One of the most compelling examples of the value of early collaboration involved a customer designing a PCB with four blind vias and a final epoxy-filled via. The initial design was not aligned with IPC-2221 and IPC-2222 guidelines, leading to significant manufacturing challenges. The board’s original design resulted in a painful 25% final yield and less-than-desirable field reliability—a costly outcome for both the customer and the fabricator.

Recognizing the issue, the PCB designer and manufacturer partnered together to redesign the board in accordance with IPC standards. The redesign addressed critical issues such as:

• Proper via configurations
• Stackup optimization
• Material compatibility

The results were remarkable. The revised revision achieved an 88% yield, a substantial improvement in manufacturability and reliability. This example highlights how proactive collaboration can transform a struggling design into a high-yield, reliable product, avoiding unnecessary costs and delays.

How to Foster Collaboration

Collaboration between designers and fabricators is essential for ensuring the success of any PCB project. Below are four proven strategies for fostering a strong partnership:

1. Engage early – Designers should reach out to their fabricators during the initial phases of a project, particularly when defining the stack-up and selecting materials.
2. Leverage expertise – Take advantage of the fabricator’s DFM and engineering support services to validate designs and resolve potential issues up front.
3. Communicate effectively – Share complete and accurate data packages, including clear design intent, specifications, and end-use requirements, to enable fabricators to provide meaningful feedback.
4. Build long-term relationships – Establishing a strong partnership with a fabricator creates a foundation for smoother collaboration on future projects, leading to continuous improvements in both design and manufacturing processes.

Conclusion

Early collaboration between designers and fabricators is no longer optional—it’s essential. The rewards of this approach are clear including:

• Reducing redesigns and production delays saves time and money
• Reliable designs that succeed on the first pass enhance product confidence
• Accelerated time-to-market provides a competitive edge
• Improved customer satisfaction and brand reputation

Early collaboration enables manufacturers and designers to focus on the ultimate prize—being first to market with a dependable, cutting-edge product that sets them apart in the industry. Start planning today to ensure your next project is a success from the first pass.

Feature Article by Gerry Partida
Summit Interconnect

Note: This article originally appeared in Design007 Magazine, March 2025.