Issue link: https://iconnect007.uberflip.com/i/1475604
28 DESIGN007 MAGAZINE I AUGUST 2022 • Using larger components: When only one component on the board had pin spacing less than 0.5 mm, it didn't save any space at all. is part needed a special paste mask and we had to have extra spacing for the masking. Replacing it with a larger pack- age saved us space on the board and cost less in manufacturing. • Using higher-temp materials: is helped the board to withstand the stresses of man- ufacturing. It cut down on stress failures and fallout, thus cutting the overall costs. • Using blind and through-vias: is improved breakout from fine-pitch parts. It wasn't as expensive as using blind, buried, and through-vias; it improved power connectivity, and saved space on the board. • Split one board into two boards: I modu- larized high-power, larger-pitch circuits and low-power, small-pitch circuits. e electrical requirements for these are different and become cost-adders for manufacturing when combined. Creating two boards, one with thick copper and larger features, the other with thin copper and smaller features, allowed each to be easily created at less overall cost. So, here's my take on how to reduce your costs: Planning Ahead is is one of the most important jobs of the program manager (PM). You'd be surprised how many DFM issues start with the PM. So, how does the PM influence the costs? • Setting the IPC classification of the design. is puts limits on everything else that follows. Class 2 is common and doesn't incur any cost adders. Class 3 will oen triple the cost of manufacturing. It can be used in specific areas only and not have too much of a cost hit. Class 1 can reduce the costs if the features (trace/space/vias/components) are larger. Classification is all about the risk factors a product can support. • Coordinating all the players for the design features—ME, EE, designer, fabricator, assembler, and test engineer. Having regu- lar design reviews along the way helps to curb cost-increasing decisions. • Setting the time frame for all processes. e PM must be aware of the domino effect. If too little time is spent on planning and design, then it can lengthen the time in fab and assembly. • How cutting-edge do you want to be? Some new processes can save time in fab and assembly, but cost time in the design and engineering phase. › is is not a bad tradeoff if you are build- ing a lot of boards (over 1,000 per year). If you're building only a few boards, then you may want to cut back on those smaller components and advanced pro- cesses. You're not going to save that much in the manufacturing processes. And they may end up costing you more. › If you're building very small products or mixed high power/high speed products, you will want to take more time in the design phase and maybe look closely at some new processes. is can help to save significant cost adders even for smaller volume products. Dummy Boards Prepare a couple of different types of dummy boards ready for quotes when qualifying a fabricator and assembler. I've heard so many comments from clients that they get vastly dif- ferent prices from fabricators and assemblers. Yes, they each have different capabilities and ways that they can or can't produce a product. • e websites will get you a lot of infor- mation about what they consider "cost adders" and their capabilities. However,