10 Common PCB Design Mistakes That Drive Up Manufacturing Costs

PCB design mistakes including thin traces, poor component placement, excessive vias, and misaligned pads, leading to higher manufacturing costs and overheating

Introduction

Designing a PCB isn’t just about routing signals. Every choice impacts manufacturing costs, reliability, and performance. Even minor mistakes can lead to expensive rework, longer lead times, and lower yields. Avoiding these PCB design mistakes can save time and reduce costs


1. Thin Traces, Thick Costs

Thin traces may save space but can lead to overheating and failure, especially in power-heavy designs. The PCB surface finish also affects conductivity and oxidation resistance, impacting long-term reliability. To prevent costly rework, ensure trace widths meet current requirements and follow manufacturer guidelines.

2. Component Placement Matters

Poor component placement complicates assembly, increasing defects and costs. DFM-optimized layouts ensure proper spacing, preventing soldering issues and pick-and-place inefficiencies. Following IPC-2221 design standards helps improve manufacturability. Early collaboration with manufacturers streamlines automated assembly and reduces redesigns.

3. Vias: Use Wisely, Spend Wisely

Blind and buried vias add complexity and cost. While useful for high-density boards, excessive use increases fabrication time and expenses. A cost-effective PCB design balances via selection with manufacturability to avoid unnecessary costs.

4. Pad Misalignment = Connection Failures

Misaligned or incorrect pad sizes lead to soldering defects and weak connections, causing high failure rates. Always verify footprints against manufacturer specifications to ensure proper alignment and prevent costly errors.

5. Auto-Router: Friend or Foe?

Auto-routing is convenient but often results in inefficient paths, excessive vias, and signal integrity issues. Manually routing critical signals improves performance and prevents unnecessary complexity. Always review auto-routed traces before finalizing the layout.

6. Clearance is Not Optional

Ignoring clearance rules increases the risk of shorts and EMI issues. Many designers try to squeeze in extra connections, overlooking manufacturer and IPC spacing guidelines. Proper clearance reduces rework and compliance failures.

7. Thermal Management: Plan Ahead

Neglecting thermal management leads to overheating and shorter product lifespan. Proper use of copper pours, heat sinks, and thermal vias improves heat dissipation. Designing for reworkability also helps prevent unnecessary scrap due to thermal damage.

8. Skipping Test Points = Costly Fixes

Skipping test points makes debugging and quality control difficult. Without proper access, diagnosing board issues becomes expensive and time-consuming. Including test points on key signals streamlines production testing and reduces troubleshooting costs.

9. Decoupling Capacitors: Placement is Key

Poorly placed decoupling capacitors cause power instability and noise, leading to unreliable performance. Placing them too far from IC power pins weakens their effectiveness. Keep capacitors close to maintain stable operation.

10. Skipping DRC? Prepare for Delays

Ignoring Design Rule Checks (DRC) results in costly errors. Small spacing violations or incorrect drill sizes may seem minor but can cause manufacturing failures. Using PCB Design Rule Checks helps optimize layouts for compliance and efficiency.


Conclusion

Avoiding PCB design mistakes ensures smoother production, better reliability, and lower costs.

Need help optimizing your PCB design for manufacturing? Contact Titoma today for expert DFM solutions and cost-effective production strategies.