Issue link: https://iconnect007.uberflip.com/i/1538269
AUGUST 2025 I DESIGN007 MAGAZINE 17 cesses. The wasted copper, laminate, chemicals, and labor could have been avoided with a well- structured, IPC-compliant design. Identifying Design Issues: Tools and Missed Opportunities The industry has developed advanced tools to identify design issues early in the process, offering the potential to correct problems before manufac- turing begins. PCB design tools like Siemens NPI (New Product Introduction) and fabrication tools like Genesis InSight or Integr8tor allow engineers to perform detailed design rule checks (DRCs) and manufacturability analyses. These tools highlight potential risks in the design, such as misaligned drill files, inadequate copper-to-edge clearances, and poorly optimized stackups. Despite the availability of these tools, many design issues go unaddressed. Rather than revise a problematic design, many designers choose simply to move forward. This decision may seem expedient at the moment, but it comes at a high cost in the form of lower yields, longer lead times, and missed delivery schedules. Moreover, when a bad design is knowingly pushed forward, sustainability is rarely considered. The deci- sion disregards the broader environmental impact of increased waste and energy consumption associated with remakes and overages. Each flawed design that proceeds to manufacturing represents a lost oppor- tunity to take sustainability seriously and to design with long-term efficiency in mind. One Example of Sustainability Cost: Fabricating Woven Glass Woven glass fiber is a key component in PCB lami- nates, providing structural integrity, dimensional sta- bility, and critical electrical insulation. However, its production is an energy-intensive and resource- heavy process that requires precision and expertise. The process begins with raw materials like silica sand, limestone, and other additives being melted ▼ F i g u re 1 : T h e c a r b o n fo ot p r i nt a n a l ys i s of a n exa m p l e 1 0 - l aye r d e s i g n w i t h re l at i ve l y l owe r y i e l d s a n d re l at i ve l y h i g h c a r b o n -fo ot p r i nt m ate r i a l s a n d p ro c e s s e s . A n a l ys i s wa s p e r fo r m e d w i t h t h e Av i s hte c h G a u s s S u st a i n a b i l i t y to o l .