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16 DESIGN007 MAGAZINE I AUGUST 2025 S ustainability has become a key focus for PCB companies seeking to reduce waste, conserve energy, and optimize resources. While many dis- cussions on sustainability center around materi- als or energy-efficient processes, PCB design is an often overlooked factor that lies at the heart of manufacturing. Good design practices, especially those based on established IPC standards, play a central role in enabling sustainable PCB production. By ensuring designs are manufacturable and reliable, engineers can significantly reduce the environmental impact of their products. Let's explore how adhering to design rules can directly contribute to sustainability and why poor designs can derail these efforts. A RT I C L E by G e r r y Pa r t i d a , S u m m i t I n te rc o n n e ct The Hidden Cost of Bad Design Poorly designed PCBs often result in low manu- facturing yields, leading to higher scrap rates. For every lot that fails, manufacturers must remake boards, consuming additional materials, energy, and manpower. This cycle not only increases pro- duction costs but also amplifies the environmental footprint of each PCB produced. For example, a design with inadequate annular rings or insufficient conductor or plane clearances may cause defects such as open circuits or shorts. Badly conceived or overly complex HDI stackups can lead to registration issues, delamination, and other non-compliances. These issues often require rework or remakes, both resource-intensive pro- How Good Design Enables Sustainable PCBs