Today’s highly advanced equipment and devices could not exist without printed circuit technologies. Shifting market demands, along with the development of increasingly smaller consumer products and medical devices, have changed printed circuit manufacturing and prompted the development of new, more efficient processes.
In this blog, we asked Tramonto’s Michael Talbot to share his insights on the technological trends, challenges, and innovations in AI and manufacturing automation that will continue to shape the industry.
Emerging Trends, New Challenges, and Trusted Processes
In any manufacturing sector, there is often a focus on developing new tools and processes. Manufacturers and their customers want to do things faster or try cutting-edge circuit technologies to support their product development.
One example of a beneficial development is 3D printing, which is often used to develop non-functional prototypes. The technology does not play a role in actual production, but it can help design teams test the sizing of a circuit design to ensure it fits in their product before sending it to a manufacturer. Michael elaborates,
“While there are cases where innovation is useful, new technologies that test the boundaries of what’s possible do not always fit into existing processes focused on quality, value, and reliability. Instead of trying to reinvent processes, circuit manufacturers and product design teams often turn to improving upon proven technologies.”
For example, new materials are continually being developed, but the use of silicone rubber remains steady for applications that require consistent, even heat distribution and compatibility with high temperatures. On the other hand, challenges with lamination methods can present opportunities to test new materials and processes that advance the industry while supporting the customers’ unique needs.
Printed Circuit Market Growth and Trends
Over the past few decades, we have noticed the most growth and technological advancement in consumer electronics and medical devices. Manufacturers of phones, tablets, and smartwatches, for example, continue to develop increasingly smaller products. Circuits designed for implantable devices, hearing aids, and other medical products are also pushing the envelope of design by requiring sometimes microscopic circuits.
Flexible circuits are the most notable technology for these products due to a flexible and space-saving design that fits virtually any shape. To accommodate shrinking footprints, we have manufactured long flexible circuits that are only thousandths of an inch wide, as well as PCBs that would fit on the tip of a pen cap.
“There are, however, limits to how small circuits can be designed while still delivering sufficient power. This type of battery technology is still developing, and we continue to learn more about it to support customers in their design and product testing.”
Measures to Improve Circuit Consistency and Quality
It is no surprise that automation has a significant role in printed circuit manufacturing. Tasks that were once done by hand using crude tools are now handled by robots that can perform tasks at speeds faster than the eye can see.
“Not all that long ago, machines could not be used to solder circuits due to the placement and precision required. Now, we have robots capable of precise placement while maintaining critical variables such as consistent heat. In the production of small and microscopic circuits, this use of automation has become extremely important for maintaining consistency and quality across large quantities.”
It is important to note that there can be a downside to manufacturing automation. When used for quick-turn prototypes or production, automation often results in low-quality circuits. Customers might receive their product faster and at a lower cost, but a much higher percentage of circuits will be unusable due to flaws or inconsistencies.
“As a manufacturer focused on quality, we believe in using automation to improve product quality rather than increasing the volume in which we manufacture circuits. When used correctly and with proper manufacturing for design assessment, these processes can help customers reach production quantities at mass pricing while accounting for quality control and the limitations of their design.”
The Role of AI and Human Expertise in Circuit Design
AI use is still relatively new in printed circuit design and manufacturing, and we have barely scratched the surface in learning what it can do. Currently, we know of very few manufacturers that use AI extensively for circuit design or manufacturing.
“Though AI technology will be an invaluable tool for the industry in the future, there will always be a human element needed.”
For example, you can train AI to look for flaws in a design, but a human will review a CAD through the lens of their expertise. They can identify potential flaws based on something they saw in a previous design, then apply their knowledge to redesign the circuit for manufacturability. Additionally, human expertise will always be needed to train AI models and aid in the development of new printed circuit design and manufacturing processes.
Advancements in Printed Circuit Manufacturing: The Final Word
We are excited to see what the future holds for circuit manufacturing. Every new design challenge presented by a customer provides an opportunity to try new technologies and improve manufacturing processes. Send us a message to learn about our processes and discuss your design with an engineer.