How to Eliminate Engineering Questions on New PCB Designs
When it comes to printed circuit board (PCB) manufacturing, few things cause more delays—and frustration—than a flood of engineering questions (EQs) following the release of a new design. These back-and-forth clarifications can extend lead times, create production bottlenecks, and inflate costs. The good news? Most EQs are preventable.
At Cleveland Circuit, we believe that collaboration and communication early in the design process can save time, money, and headaches later. Here are practical strategies to help you eliminate—or significantly reduce—engineering questions on your next PCB design.
- Follow Design for Manufacturability (DFM) Guidelines
DFM isn’t just a buzzword—it’s a best practice. Align your design with the capabilities of your PCB supplier from the start. Each shop has its own process constraints for trace width, hole size, copper weight, aspect ratio, material types, and more. Request a capabilities matrix from your fabricator and bake it into your design rules to prevent violations.
🔍 Tip: Don’t assume all board shops are the same. A design that passes checks at one supplier may trigger a dozen EQs at another.
- Provide Complete and Clear Documentation
The fastest way to generate EQs is with incomplete or ambiguous data. A complete documentation package should include:
- Gerber or ODB++ files
- IPC-compliant fabrication and assembly drawings
- Readable drill files with clear stack-up callouts
- A controlled impedance spec (if applicable)
- Material callouts, including Tg, CTI, and UL ratings
- A README or design note file summarizing special instructions
Avoid vague notes like “build to IPC standards” without specifying which class (e.g., IPC-6012 Class 2 or Class 3). Clear documentation leads to clear execution.
- Include a Stack-Up Drawing
One of the most common sources of EQs is an unclear or missing layer stack-up. Include a stack-up drawing with layer count, dielectric thicknesses, material types, and copper weights. If your design requires impedance control, this drawing is essential for proper modeling and fabrication.
⚙️ Bonus: Ask your board house to provide a pre-approved stack-up before finalizing your design. That way, you’re both on the same page.
- Avoid Conflicting Information
Don’t let multiple revisions or legacy files creep into your release package. Conflicting data between drawings, Gerbers, and documentation almost guarantees a call from engineering. Use a release checklist and ensure only the most current files are shared.
- Leverage Supplier DRC Tools and CAM Reviews
Many board shops offer free or low-cost design rule checks (DRC) and pre-CAM reviews. Take advantage of this service before sending your job to production. It’s a proactive way to catch potential issues and eliminate EQs before they start.
- Communicate Special Requirements Clearly
Need specific surface finishes, tight tolerances, or non-standard materials? Don’t bury that info in a note on page four. Highlight special requirements in your documentation summary or design note. Clear expectations reduce guesswork and eliminate follow-up questions.
- Collaborate with Your PCB Partner Early
The most effective way to eliminate EQs is to bring your PCB supplier into the process early. Sharing preliminary designs, consulting on materials, and discussing trade-offs upfront creates a partnership—not just a transaction.
Final Thoughts
Engineering questions aren’t just annoying—they can cost you valuable time and money. By following these best practices, you can dramatically improve your first-pass yield and get your boards delivered faster and with fewer surprises.
At Cleveland Circuit, we’re here to help you design smarter and build better. Need help reviewing your design? Reach out to our engineering team for a complimentary DFM review.
