Issue link: https://iconnect007.uberflip.com/i/1535183
Data Integrity Goal: No Design Errors A perfect data package must be free from design errors that result in non-functional, intermittently functional, or high-defect-rate assemblies. Ideally, the PCB should be manu- factured as-is per the provided data. However, doing so without review would oen lead to scrap or poor performance. Common design errors include: • Impedance values that contradict the pro- vided material stackup • Impedance traces missing from referenced layers • Legend ink on solderable surfaces • Solder mask encroaching on pads • Insufficient space for required fabricator markings Documentation cannot correct these issues. Instead, experienced front-end engineering teams and automated DFM tools identify and flag them via a DFM technical query (TQ). Data Integrity Goal: No File Discrepancies e ideal package contains only a single graphical data format. Today's ECAD systems can export in various formats (e.g., Gerber 274X, ODB++, IPC-2581), but sending mul- tiple versions leads to inconsistency and added verification work for manufacturers. IPC-2581 stands out as the most com- plete intelligent file format. It consolidates all required data, eliminating the need for redun- dant or conflicting documentation. For organi- zations that still require visual documentation, drawings can be generated automatically using standard or custom templates. Documentation Efficiency Goal: Eliminate Documentation (Dual Masters) Traditional documentation is oen con- tradictory, irrelevant, or redundant, slowing down the design-to-manufacturing pipeline. Many specifications captured as notes can and should be embedded directly into the design file, as they already exist in the eCAD database. Historically, technical requirements were conveyed via drawings or PDF documents. is was necessary due to the limitations of older file formats like Gerber and Excellon, which couldn't express material specs, stack- ups, or impedance models. With the advent of ODB++ and IPC-2581, most of these paper- based requirements can now be embedded and extracted digitally. Many humans and internal PDA systems still require that an electronic drawing be released. is doesn't have to change as a drawing can be automatically created from the IPC-2581 file using standard templated soware. 12 DESIGN007 MAGAZINE I MAY 2025 Figure 1: As this Pareto chart of data package defect categories shows, many issues begin at the design stage.