Issue link: https://iconnect007.uberflip.com/i/1533085
50 DESIGN007 MAGAZINE I MARCH 2025 Connect the Dots by Matt Stevenson, ASC SUNSTONE CIRCUITS Stop Killing Your Yield: The Hidden Cost of Design Oversights I've been in this industry long enough to rec- ognize red flags in PCB designs. When design- ers send over PCBs that look great on the com- puter screen but have hidden flaws, it can lead to manufacturing problems. I have seen this happen too oen: manufacturing delays, yield losses, and designers asking, "Why didn't any- one tell me sooner?" Here's the thing: Minor design improvements can greatly impact man- ufacturing yield, and design oversights can lead to expensive bottlenecks. Here's how to find the hidden flaws in a design and avoid disaster. Small Adjustments, Big Impact Let's start with the basics: Designing for yield. Small details in the layout matter, like via sizes, copper distribution, or tolerances. Designers oen underestimate the impact a small design flaw can have on the PCB manu- facturing processes, the reliability of the proj- ect, or the cost of manufacturing. A decision that does not line up with your manufacturer's core competency can lead to project delays, reworking to rectify the error, electrical opens from voided plating, electrical shorts, and