PCB Prototype Fabrication: The unexpected benefits of the iterative design loop


PCB prototyping is a beneficial activity, allowing designers to alter printed circuit board parameters, materials, and layout to maximize performance, cost-effectiveness, and product longevity. No hard and fast rule governs how long the prototype circuit board phase lasts. The short answer would be until the initial brief. Still, the beauty of prototyping means that a project's overall scope and even a PCB's specific capabilities can evolve.


Here we will illustrate and outline the details of a PCB prototype phase from a small-scale electronics company in the U.S. employing prototype PCB fabrication services from a leading PCB manufacturing company:


Prototyping example: Smart device for monitoring plants 

The product design team from the electronics company in question has established the initial product brief: To develop a plant monitor that has Smart functionality. Essential deliverables include:

  1. Be affordable for a targeted consumer group in the U.S

  2. The ability to measure moisture levels in the soil surrounding a plant

  3. Wireless capabilities

  4. Be battery-operated

  5. Compatibility with leading Smart devices (iPhone / Samsung smartphones, etc.)

Prototype circuit board - Phase 1

The electronics company has a PCB design file ready to go and has chosen a PCB prototype manufacturer that can offer rapid-turn prototyping of PCBs. With the design file submitted, the prototype PCB is produced in 24 hours. The PCB manufacturing company can conduct the first round of testing on behalf of the electronics company, and the results are quickly assessed, generating a report.

  • The device works as intended and can correctly measure moisture levels in soil. However, the design raises concerns.

  • Issue one: When tested, there is an issue with the Wi-Fi signal range.

  • Issue two: The PCB draws more power than expected, resulting in a prematurely drained battery.

The team discusses these results with their PCB prototype manufacturer and concludes that changes to the PCB will need to be made for the next phase of prototype PCB fabrication.

Prototype circuit board - Phase 2

New design goals for the next round of prototyping include implementing Wi-Fi technology instead of Bluetooth. This will significantly increase the wireless range and performance. Wi-Fi will require added power, but the team has already established that the small button cell battery has insufficient capacity to power the device for the minimum duration required. 

Now with added power, more functionality can be introduced. The design team proposes adding a temperature sensor to the device to monitor soil temperature and moisture levels. These new additions do introduce new challenges, however:

  • The PCB routing will need to be more complex 

  • Power management will need to be improved

  • Temperature readings could become inaccurate if the sensor is placed incorrectly

 Prototype circuit board - Phase 3

The PCB manufacturing company sources the new components, and revisions are made to the prototype circuit board design and layout. Once again, a new prototype is ready for testing within 24 hours. The results come back, and it’s looking perfect for the electronics company. They are confident that the device has the battery and wireless performance to meet the brief. Still, because of the benefits of prototyping, they’ve added functionality in the form of a temperature sensor. They’ve essentially exceeded the brief, and all thanks to prototyping! Mass production can now begin.


Choose your PCB prototype manufacturer wisely. 

 

In the example given above, the PCB manufacturer in question was able to add considerable value by offering rapid turn prototyping and testing services. Suppose your business is looking for a PCB manufacturer in the U.S. capable of producing rapid prototypes at an affordable cost (with no minimum order quantity). In that case, Bay Area Circuits has extensive experience helping countless businesses with prototyping and testing cycles.


Bay Area Circuits in Silicon Valley, California, specializes in quick-turn prototyping and low-to-medium volume PCB production, all under the same roof.


Choose Bay Area Circuits for fast, reliable PCB prototyping.
Location: United States

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