How To Plan PCB Projects From Design To Examples

RAYMING PCB & ASSEMBLY
How to Plan PCB Projects from Design to Examples ?

Developing a new electronics product with a custom printed circuit board
(PCB) involves extensive planning even before schematic entry begins. A
systematic approach to planning PCB projects helps avoid costly mistakes
and delays down the line.
This comprehensive guide covers how to effectively plan a PCB project
end-to-end – starting from the product requirements all the way through
fabrication, assembly, and testing. Read on to learn planning best
practices that will set your next PCB project up for success.
Table of Contents
Gathering Requirements
The critical first step is gathering detailed requirements that will drive
the PCB design, manufacturing, and testing. Key requirements to obtain:
 Input/output interfaces – What types of wired or wireless interfaces
are needed? Common standards like USB, Ethernet, WiFi determine
layout constraints.
PCB Manufacturing & Assembly Services https://www.raypcb.com/

 Component selection – Will high power, high frequency, or
space-grade components be used? Component sizes and pinouts
affect PCB design.
 Functional modes – What modes of operation are needed? This
defines use cases to design and test for.
 Performance criteria – What are the critical performance metrics
like data rates, accuracy, response times, power consumption, etc?
 Environmental factors – What environments will the product
operate in – indoor/outdoor, temperature range, vibration, etc? This
influences design ruggedness.
 Compliance – What regulatory standards like UL, FCC, CE must be
met? Compliance needs drive certain design and test criteria.
 Manufacturing volume – Will this be a short prototype run or mass
production? Manufacturing and inspection processes depend on
volumes.
 Budget constraints – What are cost targets for BOM, PCB fabrication,
assembly, etc? Costs depend heavily on design choices.
Documenting all requirements creates a product requirements
specification (PRS) that aligns cross-functional teams and ensures no gaps
in planning the PCB project stages.
Request PCB Manufacturing & Assembly Quote

Selecting Components
With requirements defined, appropriate integrated circuits, discrete
semiconductors, passives, connectors, and other components can be
selected.
 Review datasheets for specifications like performance, operating
ranges, packaging, pin counts, etc.
 Prefer use of standard components that are readily available and
qualified. Custom or obsolete parts often delay projects.
 Consider environmental needs like temperature tolerance, radiation
resistance, etc.
 Model board space needed for placements based on component
dimensions.
 Check that packaging and pinouts are compatible with PCB
assembly processes.
 Minimize different component types to reduce BOM cost and
complexity.

Judicious component selection while meeting technical requirements
optimizes downstream PCB design.
Schematic Design
The schematic captures the circuit architecture and connectivity on paper
before physical implementation.
Schematic design tips:
 Use top-down hierarchical blocks for major subsystems. This
simplifies complex designs.
 Adhere to logical grouping and naming conventions for nets and
components.
 Include test points to facilitate hardware debugging and
characterization.
 Design with manufacturability in mind. Schematics tightly
constrain PCB layout options.
 Simulate circuit performance to verify operation before prototyping.
A complete schematic allows progressing to PCB layout with all interfaces,
components, and nets logically defined.
PCB Layout

pcb layout design
With the schematic complete, PCB layout can begin. This maps the logical
schematic onto a physical board template.
Best practices for layout:
 Group related components together for efficient local routing.
 Ensure high speed paths have impedance control and isolation.
 Include modest spare board area for last minute layout changes.
 Follow all manufacturers’ design rules for trace spacing, hole sizes,
etc.
 Design for thermal management with adequate copper heat sinks.
 Minimize trace lengths for critical signals like clocks and high speed
buses.

 Review layouts regularly against requirements to avoid missing key
features or constraints.
Careful schematic-driven PCB layout avoids costly respins due to
functional or manufacturing issues.
Design Reviews
At multiple points during schematic capture and PCB layout, formal design
reviews should be conducted.
Typical design reviews:
 Requirements Review – Verify all defined requirements are properly
translated into the design.
 Schematic Review – Assess circuit correctness, manufacturability,
testability.
 Layout Review – Check form fit, tolerances, serviceability,
manufacturability.
 Safety Review – Ensure regulatory and safety standards compliance.
 Quality Review – Confirm adherence to quality processes and
documentation.
Reviews help identify issues early when they can be readily addressed,
reducing costly redesigns later.

Thermal Analysis
Thermal design is a critical aspect of PCB layouts. Excessive temperatures
can cause failures.
Thermal analysis process:
 Power Maps – Estimate power dissipation for each component.
 Heat Spreading – Ensure power planes and thermal vias distribute
heat.
 Thermal Simulation – Model temperature rises with finite element
analysis.
 Heatsinking – Add copper pads, planes, and thermal reliefs to
dissipate heat.
 Cooling – Evaluate need for fans, heat pipes, liquid cold plates, or
other cooling.
Detailed thermal design improves reliability and prevents hot spots on the
PCB.
Design for Manufacturing (DFM)

PCBs must be designed not just for function but also for
manufacturability.
Key DFM considerations:
 Manufacturer Capabilities – Understand minimum trace widths,
hole sizes, spacing, etc.
 Tolerances – Account for tolerances of ±10% or more in fabrication
and assembly.
 Panel Utilization – Layout board shape and placement for efficient
panel use.
 Split Planes – Avoid large copper fills which are prone
to etching artifacts.
 Test Points – Include test pads connected to nets for
characterization.
 Chamfers/Fillets – Use smooth corners on cutouts and pads for
better fabrication.

Early DFM analysis avoids delays and costs of design re-spins to fix
manufacturability issues.
Design for Assembly (DFA)
In parallel with DFM, assembly factors must be addressed:
 Component Placement – Ensure they are accessible by
pick-and-place machines.
 Rotation/Orientation – Define component rotation to match
assembly processes.
 Picker Access – Account for clearances required for vacuum picker
heads.
 Adhesives – Plan locations of epoxies, tapes, staking compounds.
 Standoffs – Include standoff locations for securing components.
 Test Points – Provide adequate test points for in-circuit testing.
DFA techniques result in PCBs that transition smoothly from fabrication to
automated assembly.
Cost Analysis
Performing cost analysis during the design process helps avoid cost
overruns:

 BOM Cost – Calculate total component cost based on volumes,
sourcing options.
 PCB Cost – Estimate board fabrication cost per units for chosen
manufacturer.
 Assembly Cost – Project expenses for population based on
complexity, lead times.
 Test Cost – Budget for test fixture development and unit testing
time.
 Compliance Cost – Factor in costs to achieve regulatory certification.
 Tooling Cost – Account for any custom tooling like molds, jigs,
fixtures.
Adjusting the design to align with target costs prevents budget surprises
later.
Request PCB Manufacturing & Assembly Quote
Documentation

Maintaining up-to-date documentation is crucial for smooth PCB project
execution:
 Requirements – PRS provides the foundation for development.
 Schematics – Fully detailed schematics essential for layout, BOMs,
service.
 PCB Drawings – Manufacturing drawings with dimensions, notes,
finishes.
 BOMs – Component lists with approved manufacturer parts and
volumes.
 Assembly Drawings – Mechanical assembly diagrams, staking
drawings.
 Test Procedures – Documented pass/fail criteria for every
production test performed.
Complete documentation enables clear hand-off between teams and
traceability.
Manufacturing and Assembly
With design complete, planning shifts to manufacturing and assembly.
Key planning activities:

 Fabrication Quotes – Get quotes from 2-3 manufacturers for
cost/lead time comparison.
 Assembly Quotes – Same process for assembly houses to find best
value.
 Contract Negotiation – Finalize volume pricing and terms with
chosen vendors.
 Quality Agreements – Define defect limits, corrective actions,
reliability metrics.
 Process Qualification – Audit and certify the PCB fabrication and
assembly processes.
 Logistics – Determine shipment methods and schedules to
synchronize supply chain.
Thorough planning with manufacturing partners results in quality product
build at scale.
Test Strategy
Lastly, the overall test strategy must be defined:
 Inspection Testing – Optical, x-ray inspection to check assembled
boards.
 Functional Testing – Validate operation against defined use cases.

 Environmental Stress Testing – Test under temperature,
vibration, humidity extremes per requirements.
 Compliance Testing – Certify boards meet EMI, safety standards like
CE, FCC.
 Quality Audits – Sampling based audits to confirm manufacturing
quality.
 Test Jigs/Fixtures – Design any custom rigs needed to accurately
stimulate and measure.
 Problem Reporting – Implement tracking for yield fallout and field
failures.
 Test Documentation – Detail procedures, pass/fail criteria,
equipment used.
Formal test planning reduces escaping defects and ensures robust,
reliable products for customers.
Conclusion

Planning is the foundation of PCB project success. A structured approach
spanning requirements gathering, design reviews, analysis, costing,
documentation, manufacturing coordination, and test planning prevents
problems downstream. Applying best practice project planning principles
will lead to executing complex PCB programs on time and on budget.
Frequently Asked Questions
What are some key questions to ask PCB manufacturers during the planning
stage?
Key questions are: capabilities and tolerances, lead times, change order
rules, packaging methods, quality certifications, UL listing status, design
for manufacturing (DFM) guidance, and available testing services.
What are some strategies to reduce costs during PCB projects?
Cost reduction strategies include: component standardization, dual
sourcing components, value engineering design changes, negotiating
vendor volume discounts, optimizing test coverage, and designing for
automated assembly and inspection.
How early should compliance requirements like CE/FCC be considered?
Regulatory requirements should be analyzed right at project inception to
assess needed design considerations, testing, and certification timelines

which can impact schedules. Last minute certification fails can delay
product release.
What are some pitfalls to avoid during requirements gathering?
Pitfalls include: unclear or conflicting requirements, leaving requirements
unvalidated, excluding stakeholders, siloed teams lacking alignment,
scope creep due to late additions, and failure to baseline requirements.
How can Fabrication and Assembly process capabilities be accounted for?
Engage vendors early for capabilities guidance. Perform process
qualification audits. Review DFx guidelines. Define quality agreements
clearly. Implement change control systems. Utilize manufacturability
simulation tools during design.
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Examples
2. How Arduino Python Projects are Impacting Electronic Circuit
Design
3. How To Plan Stackup For Rigid Flex PCB
4. Top Examples and Applications of IIoT Manufacturing

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RAYMING PCB & ASSEMBLY

How to Plan PCB Projects from Design to Examples ?

(PCB) involves extensive planning even before schematic entry begins. A

systematic approach to planning PCB projects helps avoid costly mistakes

and delays down the line.

This comprehensive guide covers how to effectively plan a PCB project

fabrication, assembly, and testing. Read on to learn planning best

the PCB design, manufacturing, and testing. Key requirements to obtain:

 Input/output interfaces – What types of wired or wireless interfaces

are needed? Common standards like USB, Ethernet, WiFi determine

PCB Manufacturing & Assembly Services https://www.raypcb.com/

 Component selection – Will high power, high frequency, or

space-grade components be used? Component sizes and pinouts

affect PCB design.

 Functional modes – What modes of operation are needed? This

defines use cases to design and test for.

 Performance criteria – What are the critical performance metrics

like data rates, accuracy, response times, power consumption, etc?

 Environmental factors – What environments will the product

operate in – indoor/outdoor, temperature range, vibration, etc? This

influences design ruggedness.

 Compliance – What regulatory standards like UL, FCC, CE must be

met? Compliance needs drive certain design and test criteria.

 Manufacturing volume – Will this be a short prototype run or mass

production? Manufacturing and inspection processes depend on

assembly, etc? Costs depend heavily on design choices.

Documenting all requirements creates a product requirements

specification (PRS) that aligns cross-functional teams and ensures no gaps

in planning the PCB project stages.

Request PCB Manufacturing & Assembly Quote

PCB Manufacturing & Assembly Services https://www.raypcb.com/

With requirements defined, appropriate integrated circuits, discrete

semiconductors, passives, connectors, and other components can be

 Review datasheets for specifications like performance, operating

ranges, packaging, pin counts, etc.

 Prefer use of standard components that are readily available and

qualified. Custom or obsolete parts often delay projects.

 Consider environmental needs like temperature tolerance, radiation

 Model board space needed for placements based on component

 Check that packaging and pinouts are compatible with PCB

 Minimize different component types to reduce BOM cost and

PCB Manufacturing & Assembly Services https://www.raypcb.com/

Judicious component selection while meeting technical requirements

optimizes downstream PCB design.

The schematic captures the circuit architecture and connectivity on paper

before physical implementation.

Schematic design tips:

 Use top-down hierarchical blocks for major subsystems. This

simplifies complex designs.

 Adhere to logical grouping and naming conventions for nets and

 Include test points to facilitate hardware debugging and

 Design with manufacturability in mind. Schematics tightly

constrain PCB layout options.

 Simulate circuit performance to verify operation before prototyping.

A complete schematic allows progressing to PCB layout with all interfaces,

components, and nets logically defined.

PCB Manufacturing & Assembly Services https://www.raypcb.com/

pcb layout design

schematic onto a physical board template.

Best practices for layout:

 Group related components together for efficient local routing.

 Ensure high speed paths have impedance control and isolation.

 Design for thermal management with adequate copper heat sinks.