IPC International Community magazine an association member publication
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30 I-CONNECT007 MAGAZINE I FEBRUARY 2026 D R I V I N G I N N OVAT I O N Size Matters Navigating the Challenges of XXL PCB Production In high-end electronics, complexity is often measured in microns. However, when those microns are spread across a massive surface area, the engineering challenge fundamentally changes. Imagine two panels: Both are highly complex, fea- turing 4-stage build-ups, 2-mil line and space pat- terns, 2-mil microvias, and through-holes with a demanding 1:30 aspect ratio. The first is a standard panel populated with many small 2′′ x 2′′ PCBs. The second is a single, massive PCB measuring 45′′ x 24′′. While the technical specifications are identical, the production risk is not. On the multi- unit panel, a local defect might only scrap a small percentage of the board. On the XXL panel, a single mistake in any location and at any stage—mechanical, chemical, or opti- cal—leads to a complete failure of the entire PCB. In the PCB industry, size definitely matters; yield, stability, and accuracy discus- sions move to a completely different level when working with "big iron." How do we maintain precision and increase yield for these giants? Consider the critical considerations for XXL production. Figure 1: a) Standard panel populated with many small 2′′ x 2′′ PCBs; b) a single, massive PCB measuring 45′′ x 24′′. BY KU R T PA L M E R , S C H M O L L A M ER I CA