A range of different materials can be used when manufacturing circuit boards. However, they are not all the same. Each material brings something different to the table in terms of performance, tolerances, durability, and more. An informed decision here will maximize performance and durability, reduce weight, and ensure that your design performs to expectations.

Board Types

Circuit boards come in a wide range of types and are classified by component location, stack-up, design, bendability, strength, and electrical functionality. Before choosing a material, make sure you know which classification your design falls into, as this will affect material choices and other decisions.

FR-4

FR-4 is a commonly used material in the design of circuit boards. It is actually made of fiberglass (technically a glass-reinforced epoxy laminate), which means it is relatively lightweight and affordable. For this reason, it is often used in lower-end consumer electronics. The letters FR indicate that this material is also flame retardant, which can be important in applications where heat dispersal is a consideration. It is also known for its high mechanical values, as well as its ability to insulate and perform well even in more humid conditions. However, it may not have the thickness, durability, or capacity for higher-end or higher-performance applications.

When to use it: use FR-4 material in products where cost is a consideration, but you want effective performance across a wide range of applications. Typically, you’ll find FR-4 used in substrate/laminate boards. We recommend it for standard circuit boards.

Rogers Material

The Rogers company also manufactures material for circuit boards. The company offers several options, but one they are best known for is PTFE (Teflon). Teflon costs more than FR-4, but it provides better performance for RF circuit boards because it has a lower signal loss rate. Other advantages include a wide range of dielectric constant values, improved management of heat, and better control over impedance. The trade-off is the higher cost, coupled with slightly more weight.

When to use it: use this material in applications where power management is important, as well as where RF, microwave, or high-performance functionality are necessary. Note that this is a good material for mobile use, too. Typically used in laminate boards, we recommend this option for high frequency, microwave, and high-power situations.

Metal

Metal is an option for the base of circuit boards. So-called “metal core” boards offer greater heft, but also provide better durability and strength. Most are made from aluminum, but alloys exist that can be used instead. Typically, these boards feature the metal base layer, a second layer of conductive dielectric material, and then the final layer of copper on the top. Metal core circuit boards are widely used in solid-state applications, and in use cases where ceramic substrates cannot be used.

When to use it: metal core circuit boards are well-suited for LED applications, but can also be used for other lighting applications, and they also play a role in automotive electronic design.

HDI

HDI, or high-density interconnector, is yet another option for circuit board design. The name says it all – this material offers a high line distribution density and is often used in situations where designers need to reduce weight and size without sacrificing electronic performance. HDI can make use of blind and buried vias, as well as microvias, vias in pad, and through vias from surface to surface.

When to use it: use HDI where density is a consideration, as well as when size and weight are serious concerns. Note that HDI also offers reduced heat transfer included stress.

High Tg

As the temperature of the circuit board and surrounding environment rises, the material of the board’s base layer actually shifts states. The higher the temperature at which the material can remain rigid, the better performing the material will be for board design. Of course, in low-temperature environments, this is not much of a concern. However, with high-temperature environments, the glass-transition temperature (Tg) is important. High Tg materials offer the temperature resistance required for these applications, and they are beginning to be more commonly used across industries.

When to use it: high Tg materials are all about heat control, so this material is well-suited for designs where stability at high temperatures is critically important. We recommend this material for high density needs.

A Note on Solder and Toxicity

Soldering circuit boards can expose you to lead-carrying fumes (lead is sometimes contained within solder). Since any circuit board will require soldering, always solder boards in a well-ventilated area, while wearing appropriate protective gear.

A Full Range of Capabilities for Circuit Boards

At Advanced Circuits, we offer an end-to-end service for your needs in designing and manufacturing circuit boards. From choosing the right material to determining the right number of layers to full PCB assembly, we offer fast turnarounds and affordable pricing. No order is too large or too small. All circuit boards are manufactured within one of our US-based locations, which allows us to manufacture circuit boards for virtually alllayout projects, including DOD contracts.

Layout and Design Help for Circuit Boards

We believe in giving our customers every advantage possible. We understand that designing circuit boards can be incredibly complex, time-consuming, and frustrating. To help ease that burden, we offer free access to PCB Artist — our intuitive, unrestricted PCB design software — to walk you through the entire design process. Create designs of up to 28 layers, import from Eagle, and access a library of over half a million parts all in one place.

Let’s look at some of the biggest benefits of using high-quality PCB layout software for your designs.

Reduce the Complications of Design

As mentioned, designing a printed circuit board is not easy. There are many elements that need to be considered during the construction of the board and it gets complex rather quickly. Using quality PCB layout software helps to strip away those complications. Everything is digital and can be changed, updated, and manipulated quickly and easily. It becomes easier to keep track of everything you are doing during the design process. Many find that using PCB layout software helps them to work faster because they know that they can change things so easily if needed.

Find and Fix Errors Early

When you are using PCB software, you will likely find that you are making fewer errors. This is because it is easier to keep track of what you are doing, and software can look for compatibility problems and errors. It can point out those errors and, in some cases, even offer fixes. By finding these issues early and fixing them, it means that you will be able to move on to production faster than you would have otherwise. It also means that you are not going to be spending money making prototypes, or a run of thousands of PCBs, that have errors.

Save Time and Money

Because you are working in a digital space, it also means that you are saving money on your own materials. You can create the board virtually, test it in the virtual space and have it double-checked, and then order a prototype to use. Because the software helps to reduce complications, it means you are not spending as much time with back and forth on the design process. You can fix the errors faster, which means you can move ahead with an order to create the products you need. You are saving time and money by using PCB layout software.

Try New Ideas

Working with PCB layout software also means you are capable of thinking outside of the box with your design ideas without any risk. You can create a design and test it virtually to see whether it will work or not. This gives designers more freedom than they might have had otherwise.

What Should You Look for When Choosing PCB Layout Software?

• Cost: Today, there are many options on the market for this type of software, but you need to be sure you are choosing an option that will provide you with the results you need. One of the first things that you are likely to think about when it comes to choosing software will be the cost. This is natural. Whether you are a solo hobbyist creating your own PCBs or you are a large company that is in need of PCBs for new devices you are making, price is important.

The truth of the matter is that the prices for software can vary. There are some options that are quite expensive, and most people do not want to spend $1,000 or more on software. Fortunately, there are free options, as well, such as PCB Artist. Keep in mind that cost does not mean quality. An expensive piece of CAD software will not have the capabilities of free software that was designed specifically for PCBs.

• Features: Regardless of which type of software you opt for, you will want to be sure that you are choosing an option that has all of the features you need. Compare the software you are considering to the other choices on the market to see that it has what you require. Does it offer Gerber format files? Does the software provide design rule checks and support? Does it offer integrated schematics? Will it have a library manager? How large is the library? Can you create the types of PCBs that you need with the software or not?

• Ease of Use: Additionally, you will want to have software that is easy to use. Some software will have a steeper learning curve than others, but it should not be so complicated that you have to spend weeks trying to figure out how to use it correctly. The software should offer a guide to help you get started. If the company offers video tutorials, it is even better.

Once you have the software, you will want to familiarize yourself with it by using the guide or the tutorials previously mentioned. Do this before diving in and trying to create an important PCB design. This ensures that you will have a good understanding of how to use the software and where to find various features when you start using it for PCB design.

Make PCB Artist Your PCB Layout Software Choice

There are many options on the market for CAD software that could be used for PCB design, and there are some specifically made PCB layout software choices available. With all of those options, why should you choose PCB Artist from Advanced Circuits? One of the major reasons is the fact that the software will not cost you a thing. We offer free software, so you can easily design quality PCBs that will work well once they are manufactured.

Take the time to check out the features of our free PCB software including more than half a million parts in the library and the free technical support we offer. Whether you are new to the field or you have been creating printed circuit board designs for years, this will soon become the first piece of software you consider when you are designing a new PCB.

Whether you’re an expert engineer or an at-home inventor, you’ve likely designed PCBs that fail due to a short circuit or burnt-out component. PCB designs are incredibly intricate, and you’re not alone in your trial and error. Circumvent some of these hard lessons by checking out these tips to optimize your PCB layout for a better performing PCB.

Research                                                                                                                   

Before you begin drawing up the plans for your next PCB, pause for a moment to consider why. Is your goal to improve an existing circuit board? Are you dreaming of an entirely innovative concept? Whichever your reason, make sure you know your end goal and research whether there are existing circuit board templates that you can use. This pre-work will save you a ton of time and keep you from reinventing the wheel if a solution already exists. You’ll also avoid repeating the mishaps of others when designing your PCB layout.

Create a Blueprint

Once you’re set on the outcome you’re hoping to achieve, it’s time to put your ideas into something tangible. Start with a hand-drawn sketch to map out your circuit board. This will allow you to see the flow and catch any errors before adding in the complication of technology. You can also have colleagues or other PCB hobbyists review your circuit board layout ideas for input before creating your virtual design.

Use a (Free) PCB Software

With your blueprint in hand, you’re ready to start designing the layout of your PCB. The best way to create a PCB layout is by using free PCB design software, like Advanced Circuit’s PCB Artist. PCB design software, like PCB Artist, will give you access to a components library with over 500,000 parts. It’s incredibly easy to search for a previously used component, add it, and rearrange as needed for your PCB layout. Never pay money to use PCB design software, as there are so many excellent free choices on the market.

This digital blueprint that you create using a PCB software is called a schematic. In your schematic, you’ll place your components, connectors, connections, and power sources. Eventually, this will become your PCB design that a manufacturer will use to create your PCB.

Most free PCB design software also comes with a design rule check so you can be confident that your PCB layout works and can be produced by the manufacturer of your choice.

Placement

The placement of your components during the schematics stage is incredibly critical to the viability of your PCB. Typically, you want to start by placing your most essential elements first, and then go from there with any flairs or add-ons. Keep in mind that you don’t want to overcrowd your PCB. Placing components and active elements too close together can result in high temperatures. Overheating your PCB can cause components to burn and, ultimately, lead to your PCB failing.

You’ll also want to check with the manufacturer, and during the design, rule check to see if there are placement restrictions. In general, you want to leave at least 100 mils of space between any component and the edge of your PCB. You also want to evenly space out your components and organize so that like-components are oriented the same direction, as possible.

Routing

As you plan and design your PCB’s layout, you’ll want to consider the different routing options and specifications. On a finished PCB, the routing is the copper traces that run along the green board and indicate the flow of electricity between the components. The general rule of thumb is to make the route distance between elements as short and direct as possible. You also want to make sure that you make your traces wide enough to handle the high temperatures in an electrical circuit. When in doubt about your PCB overheating, you can always add in via, or holes, to channel electricity to the other side of the PCB.

Layers

Thanks to advances in our scientific understanding of electricity and circuits, we can now easily manufacture PCBs with multiple layers. The more layers you have on a PCB layout, the more complex your circuit will be. Extra layers allow you to add in more components and tends to have higher connectivity.

Multilayer PCBs appear in more sophisticated electrical devices, but if you find your PCB layout is becoming overcrowded, this could be an excellent way to problem-solve. Multilayer PCB designs do come with higher costs, but Advanced Circuits offers excellent deals on two and four-layer PCB fabrication.

PCB Manufacturer

You’ve put in the hard work and effort to design your PCB, so make sure you select a manufacturer that can bring your plan to life. Different PCB manufacturers use different fabrication processes and use varying qualities of components. It would be a shame to have an incredible PCB layout, only to receive a low-quality product with a lousy soldering job or faulty components. Choosing a manufacturer that uses surface mounting technology is your best bet for a PCB that precisely represents your PCB layout. This fabrication method is mostly automated and reduces the risk of human error when creating your physical PCB.

Create a Prototype

Even if you’re 100% confident in your PCB, it’s always a good idea to order a prototype. Even experts know that you’ll likely want to make tweaks to your PCB design once you see how your prototype performs in its given application. After testing out your prototype, you can go back to the drawing board and update your PCB layout for optimal output.

Advanced Circuits Can Help

Advanced Circuits is the third largest PCB manufacturer in the U.S. Their company has you covered from beginning to end in your PCB layout process. You can utilize their free PCB design software and file check to ensure your layout is bug-free and ready to go. Advanced Circuits has an incredibly accurate fabrication process that will ensure your PCB is delivered precisely as you designed it.

Check Manufacturer’s Tolerances & Capabilities Before Getting Started on Your PCB Layout

It may be best to review your PCB manufacturer’s capabilities and manufacturing specifications to set up your PCB layout software accordingly before you start.  If you already have a completed PCB layout and would like to check that it meets all manufacturing requirements, you can use our FreeDFM tool to upload your Gerber files and run a manufacturability check within minutes.  You will receive a detailed report of any manufacturability issues found in your PCB layout delivered directly to your inbox.  Each time you run a PCB layout through the FreeDFM tool you also receive a discount code to use on your PCB fabrication order with Advanced Circuits for up to $100 off.

Determine the Number of Layers Needed for Your PCB Layout

It is important to determine the number of layers needed for the PCB layout that will best fit your application and functionality requirements.  While more layers can help accommodate more complex designs and functionality with a smaller footprint, keep in mind that more conductive layers can also increase the cost of production.

Consider Space Requirements for Your PCB Layout

Calculating the physical space that your printed circuit board layout can take up is key.  Depending on the final application and requirements, space can be a limitation and cost driver as well.  Consider more than just the space needed for the components and their tracks, but also the circuit board mounting requirements, buttons, wires, and other components or other circuit boards that are not part of your PCB layout.  Estimating the size of the board from the beginning can also help you calculate the cost of production.

Identify Any Specific Component Placement Requirements

One of the key steps in the circuit board layout process is knowing how and where to place your components especially when the location of a specific component is mandated by factors outside of the functionality of the circuit board itself; for example buttons or connection ports. At the beginning of your circuit board layout process, you should make a rough plan which will detail where the major components will be placed, this way, the most convenient design can be assessed and used.  Try to always leave at least 100 mils between components and the printed circuit board edge and begin by placing components that require a specific location first.

Printed circuit board (PCB) layout may be considered sort of an art form by circuit designers, and there is much truth to that. Creating the most reliable, functional, yet cost-effective circuit and finished PCB can be a challenging task, especially in today’s demand for increasingly-complex requirements for compact, light-weight, even flexible boards.

One of the first considerations in the layout of the PCB is size and shape. The end result must accommodate the environment where the board will be installed and utilized, driving the design process. Space considerations may warrant the use of multi-layer or high-density interconnect (HDI) designs. Some projects call for specialized board shapes and weight limitations, making layout particularly challenging.

Although this may not be a major consideration when designing the initial circuit for functionality, in such cases as prototype design, it becomes a higher priority when laying out PCBs for production manufacturing.

Consider your fabricator in the PCB layout phase. Not all manufacturers can produce higher-count multi-layer boards or HDI PCBs. PCB layout design that calls for technologies such as flex or flex-rigid construction for the most part will need to be vetted with the proposed vendor, to ensure the layout design and material requirements can be accommodated.

Special requirements such as a need to incorporate lead-free construction or otherwise avoid potentially hazardous materials can be key points in making layout and construction decisions.

Technical PCB Layout Issues

Other more technical factors to consider in PCB layout:

• Trace widths
• Spacing between traces
• Tolerances for electrical factors that may influence board functionality
• Clearance of traces and components to board edge

Component availability – hard-to-find or specialized components can significantly increase the cost of the final board. Where high numbers of boards are expected to be produced, this can be a major concern, if lower-cost alternatives may be available.

Construction methodology – PCB layout is dependent largely on the physical construction of the boards: through-hole assembly, surface-mount technology (SMT), or a combination of the two. Multi-layer and HDI board designs have grown in use rapidly in recent years, with many specific layout requirements for those technologies.

Importance of PCB Layout

Lack of efficient and accurate layout can result in nearly infinite problems, among them:

• Electromagnetic interference from conflicting components or trace placement
• Conflicts from components on opposite sides of the board
• Rework by designer and delays in manufacturing
• Limited board functionality
• Total board failure

Solving Many PCB Layout Problems

Sophisticated computer aided design (CAD) and computer aided manufacturing (CAM) software systems are now available and in use by most PCB designers and manufacturers. Such specialized programs have many advantages over traditional engineering methods:

• Drag and drop design – place components easily and accurately, then let the software generate the traces for connections. Move or add components easily and instantly.

• Validation of layout – tolerances, compatibility, component placement, and more are verified during design, and prior to releasing the PCB for manufacturing, even for prototypes.

• Reuse – once a layout has been approved and saved, it can be reused as a template for new PCB projects, and utilized by other engineers.

• Efficiency – using such specialized programs can speed development, reduce errors, and result in faster time to market.

• Cost savings – efficiency equates to savings in re-design or manufacturing errors.

• Error detection – basic errors are caught in real time, avoiding defects in manufacturing or delays when fabricators detect them.

• Rule creation – many of these programs support creation of custom rule sets specific to a designer’s purposes. Creating these rules and storing them allows sharing among designers and enhances the functionality of the software.

• Documentation – designs can generate detailed documentation on component use, error reports, design status, version control, and more.

• Generation of manufacturing files – create Gerber files or other formats for the manufacturer quickly and easily, ensuring accurate specifications for fabrication including component placement, via specifications, traces, silk screens, solder masks, and drill files.

Always keep Design for Manufacturing (DFM) in mind in PCB layout and design. The most brilliant and creative PCB layout is of little value if it either cannot be manufactured within the project budget, or is not feasible for manufacturing by the designated fabricator.

The ability for a printed circuit board designer to collaborate with the rest of his or her team is essential for on-time product delivery and quality. As electronic products hitting the market need to be faster and smaller than their predecessors in order to gain adoption, engineers must continue to find new ways to pack in necessary components while adhering to new product casing and size requirements. In order to do this efficiently, everyone involved in the supply chain must be able to easily share and transfer ideas and data that are vital to the PCB production process. Additionally, using a PCB design system such as PCB Artist™ that includes access to an extensive components library helps you find the parts you need to ensure your circuit board will be able to succeed in its intended application.

Moving From Concept to Finished Printed Circuit Board

All of your projects and products start out in the conceptual phase. Once your team has decided on an idea and worked out ways to develop the product, you will need to begin on a design for a printed circuit board that maximizes efficiency and performance while solving challenges such as space limitations and heat production. After these challenges have been sorted out and your team is ready to move forward, the PCB manufacturing experts at Advanced Circuits make it easy to submit your files, receive a quote, place an order and get your boards quickly. This way you get the PCBs you need without delay so you can focus on the next stage of product development. To get your questions about PCB production answered, contact a representative today.

Learn More from Experts at Advanced Circuits

Pulsonix was designed on the principles of being easy to use, designed for both casual and professional users and being compatible with design and library data from key EDA products. To learn more about the software, contact the experts at Advanced Circuits. You will be able to download a free trial demo and talk to a sales person to understand the benefits you can expect.

When designing your custom printed circuit boards, you want to get the most functionality while also being able to have easier assembly. Using copper fill, for example, can help reduce heat and increase efficiency in your system. Some parts, including motor drivers and voltage regulators, get hot during usage. Placing copper fills under the chips allows you to be able to divert heat away and cool down your system. You can learn more about copper fill and PCB design by working with an expert manufacturer at Advanced Circuits. You can also learn more tricks on how to make your PCBs more efficient.

Designing PCBs with Help from Advanced Circuits

When you work with Advanced Circuits, you can get help with designing and laying out your printed circuit boards. You can use free PCB layout software to design your custom PCBs before placing your order. This lets you see any manufacturability issues before you order so you can avoid holds and get the boards you need quickly. Contact a representative today for more information.