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MARCH 2025 I DESIGN007 MAGAZINE 25 Enhanced DFM Fabricators' advanced CAM (computer- aided manufacturing) DFM tools provide valu- able input on design rules and constraints spe- cific to their processes, such as minimum trace widths, spacing, and drill sizes. ese 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 fabrica- tion, allowing designers to identify problem- atic 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 sim- ulation, 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 e cost benefits extend beyond direct man- ufacturing expenses. Reliable first-pass yields minimize wasted materials, reduce produc- tion delays, and prevent the cascading effects of redesigns on other projects. is 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 cus- tomer designing a PCB with four blind vias and a final epoxy-filled via. e initial design was not aligned with IPC-2221 and IPC-2222 guidelines, leading to significant manufactur- ing challenges. e board's original design resulted in a painful 25% final yield and less- than-desirable field reliability—a costly out- come 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. e redesign addressed critical issues such as: • Proper via configurations • Stackup optimization • Material compatibility e results were remarkable. e revised revision achieved an 88% yield, a substantial improvement in manufacturability and reli- ability. is 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 fabri- cators is essential for ensuring the success of any PCB project. Below are four proven strate- gies 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.