Creating a really good architecture, schematic and PCB design is not easy. You have to take into account not only functionality but also safety, and the documentation should be clear and descriptive so that there are no problems in production.
When we develop and design electronics at our company, we have several stages of checking to make sure that the design we put into production does not contain unnecessary errors.
For clients who, unlike us, do not have years of experience in the field and a developed system of control, the preparation of a quality design can be not only time-consuming, but often complications arise because some things are overlooked or misunderstood due to ignorance. A design error is often not discovered until the prototype passes through the testing room or even during mass production. And by then it’s too late.
Our many years of experience in the development and manufacture of custom electronics for industries ranging from transportation to medicine show that it is far better to do a schematic and PCB design review at the outset, before proceeding to prototyping. Unfortunately, many customers come to us only when they have failed certification or when the product is not working reliably in practice and are struggling with what to change.
Each design is carefully checked against our internal checklist, which can have up to sixty items (depending on the complexity and status of the design). We don’t just rely on automated design software checks, but everything is reviewed by our experts. What are the main items we focus on and why?
The schematic must not only be electrically correct, but also clear
We check that everything is wired correctly, that there are no missing protection elements (from properly sized fuses to ESD protection), that the power supply branches correspond to the needs of the circuits and are correctly designed in terms of stabilization and filters, and that the components are not overloaded and overheated. However, an experienced engineer also evaluates readability – whether the design is logically structured, easy to follow and meets professional standards. It’s not just about aesthetics – a clear layout speeds up development, testing and future servicing.
Board layout: current flow, interference, immunity
PCB layout is not just about fitting everything on the board. We check path widths according to current load, ground plane conduction, separation of sensitive signals, return currents and possible loops. We look at whether the design is resistant to interference (EMI), whether it can be fitted without complications and whether its structure matches the chosen manufacturing technology. For power circuits and fast digital signals, the correct layout is often crucial.
Will the production go smoothly, or do we need to change something?
It often happens that we get a design that is well wired, but the design is not easy to manufacture, does not respect DFM/DFA (Design for Manufacturing/Assembly) principles – for example, components are too close together or at the edge of the PCB, which complicates automatic assembly, or a solution is chosen that unnecessarily increases the number of manufacturing steps… If it makes sense, we suggest optimization, as well as if the use of atypical or difficult to find components is envisaged. For components we are able to come up with a substitute that is cheaper, we can also estimate whether an alternative with worse parameters could be used in a given case, but which will be sufficient. Because we have our own production, feedback is provided by people with practical experience.
Safety is key
In each proposal, we verify that it meets safety requirements – in particular, the isolation distances between safe circuits (e.g. SELV/PELV) and circuits with dangerous voltages (e.g. mains part), or between different potential levels, which require defined air and surface paths (clearance and creepage), protection or often neglected fire safety. We know the current standards and what is required for certification (e.g. EN 60601-1 for medical equipment, EMC standards, safety standards for consumer electronics, etc.).
We also check the availability and durability of components
A component that is available today may not be on the market in a few years. We try to verify the life cycle status of components (e.g., active, not recommended for new designs, EOL – End of Life), although manufacturers do not always provide exact end-of-life dates. For critical components, it is therefore advisable to also consider “second source” suppliers or alternatives, or just to have an idea of how challenging the design change procedure will be in case of a supply failure and derive the necessary pre-supply from that. This is particularly crucial if you plan to produce the electronics in question over the long term or in large batches.
Is testing of finished circuit boards thoughtful?
A good design assumes that finished PCBs will undergo testing. As part of the design review, we evaluate whether test points are available on the board, whether the documentation is readable, and whether important signals and power branches can be easily measured. During the redesign, we can modify the design to make testing faster, easier and more reliable.
What the customer gets from us
The result of the design review is a clear technical report that summarizes the identified deficiencies and recommends specific modifications. This can include a consultation where we go through the design together – explaining the reasons for the proposed changes and helping to decide which ones have a major impact and which are appropriate but optional.
A design review can be the start of a new collaboration – we will modify the design together, produce a prototype and prepare it for certification and mass production.
Design review is not just a list of pros and cons of the evaluated design. We project our technical expertise, manufacturing experience and ability to predict. It’s what makes the difference between a design that works on the table and one that passes certification without a hitch, can be produced cheaply and without a hitch, and can stand up to live use.
If you want to make sure your proposal is OK – get in touch. We’ll take a close look at it and help you spot weak spots before it starts costing you time and money in production.
