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60 PCB007 MAGAZINE I AUGUST 2025 D R I V I N G I N N OVAT I O N Depth Routing Processes: Achieving Unparalleled Precision in Complex PCBs by Kur t Palmer, S chmoll America In PCB manufacturing, the demand for increas- ingly complex and miniaturized designs continually pushes the boundaries of traditional fabrication methods, including depth routing. Depth routing is indispensable in several key PCB applications: • Rigid-flex PCBs: These hybrid boards combine rigid sections with flexible interconnections, requiring precise depth routing for removing the "cup" on top and/or bottom of the flex part. • PCBs with cavities: Cavities are strategically created within PCB layers to integrate or embed components directly into the board. • Copper coin PCBs for heat sinks: In high- power applications, copper coins are often embedded within PCBs to serve as highly efficient localized heat sinks. Depth routing is used to create precise pockets for these coins, ensuring a perfect fit. Success in these applications demands not only on robust machinery but also sophisticated control functions. PCB manufacturers rely on advanced machine features and process methodologies to meet their precise depth routing goals. Here, I'll explore some crucial functions that empower manufacturers to master complex depth routing challenges. Depth Routing With a Second Measuring System A common scenario in depth routing involves creating a constant depth of cut, even when the PCB panel itself is not perfectly flat—a frequent occurrence in manufacturing. In such cases, relying solely on a pre-programmed Z-axis depth from a fixed reference point can lead to inconsistent results. To overcome this, machines use a second mea- suring system, typically involving a pressure foot equipped with a specialized insert or brush that