PCB Chat

The next two episodes of Reliability Matters will be all about contract manufacturing, an area that can make or break the reliability and success of a product.  Mike Konrad's guest on this episode is Raymond Novara, founder and owner of East End Assemblies, a US-based contract manufacturer recognized for its focus on quality, customer service, and compliance with AS9100 and IPC standards. During our conversation, Raymond talks about key questions that every OEM should be considering: What are the best practices for selecting a contract manufacturer? What common mistakes do companies make when working with a CM—especially in communication and hand-offs? How can design-for-manufacturability feedback prevent problems down the road? What should customers know about transitioning from prototypes to volume production? And how can contract manufacturers help ensure long-term product reliability, not just passing initial tests? If you’re an OEM evaluating partners, an engineer preparing to hand off a design, or someone interested in how contract manufacturers contribute to product reliability, this episode is packed with insights.

Note: This is the fourth of four episodes on the subject of soldering materials.   Today, we're diving into a topic that's reshaping how we think about thermal management, energy efficiency, and long-term performance in electronics manufacturing—low temperature soldering. Joining Mike Konrad is Dr. HongWen Zhang, principal metallurgist and R&D manager of the Alloy Group at Indium Corporation.   Dr. Zhang is not only a seasoned materials scientist with a Ph.D. in materials science and engineering, a master’s in materials science and engineering and in mechanical engineering and a bachelor’s in metallurgical physical chemistry he’s also coinventor of Durafuse, a family of solder alloys that are redefining what's possible at low reflow temperatures—which, reportedly, does not compromise reliability.   In this episode, we’ll explore how low temperature solders are helping manufacturers lower energy consumption, protect heat-sensitive components, and still meet the rigorous mechanical and environmental demands of today’s electronics—from wearables to wafer-level packaging. We’ll also talk about the challenges of brittleness, drop shock resistance, activation and encapsulation of no clean activators, and how cutting-edge materials research is solving problems that used to be considered trade-offs.   Whether you’re a reliability engineer, a process expert, or just solder-curious, this episode is packed with insights you won’t want to miss.  

Today’s guest is Matthias Wagner, chief executive and cofounder of Flux. Flux is maker of a Agentic AI-based PCB design platform and programmable simulator that runs in a browser environment. Regular listeners may know we have spoken with Matthias a few times in the past, most recently in February 2024. Since we last spoke, Flux has built out its platform with a variety of tools for design planning, parts searching, netlist generation, design review, firmware coding and testing and debugging, to name a few.   We discuss AI-powered PCB design challenges Language prompting capabilities  Democratization of product design, and Technical specifications and platform limits.      

This is the third of four episodes on the subject of soldering materials. Today, we’re continuing our deep dive into the world of soldering materials, from advanced alloys and flux chemistries to global manufacturing strategy and materials innovation, with one of the industry’s most respected leaders. Joining Mike Konrad is Ross Berntson, president and CEO of Indium Corp. Berntson has been with Indium for nearly 30 years, starting as a product specialist and rising through the ranks with leadership roles in product management, technical support, and international operations. He even spent time leading Indium’s Asia Holdings while based in Singapore, strengthening the company’s presence across Southeast Asia. In his current role as CEO, Berntson sets the strategic direction for a global materials powerhouse, one that’s known not only for its high-performance soldering products but for its commitment to innovation, collaboration, and engineering support through the company’s “One Engineer to Another” philosophy. Berntson holds degrees in chemistry, teaching and an MBA from Cornell University, where he earned several prestigious academic awards. He’s also deeply engaged in both the electronics industry and his community, serving on multiple boards and leading with a strong emphasis on culture, opportunity, and respect, the core of what Indium calls “The Indium Way.” In this episode, we’ll discuss how soldering materials are evolving to meet the demands of modern electronics, from miniaturization and harsh environments to UHDI and advanced packaging. We’ll also talk about Indium’s unique positioning in the industry, the challenges of global supply chains, and what the future of soldering looks like from the vantage point of a company that’s helped shape it.

Wally Rhines joins Mike Buetow each quarter to share details from the latest ESD Alliance report on sales of PCB design software, computer-aided engineering tools, semiconductor tools, related IP and services, and employment. This chat, we discuss the long PCB/MCM design tool rally, a massive jump in employment. broader strength across the ECAD industry, and the effects US policies toward China are having on the market.  

In this episode, Mike Konrad is joined by Chris Ward, founder and managing director of Solderking Assembly Materials, a UK-based manufacturer of solders and chemical consumables for electronic, electrical, and engineered assemblies. Ward brings decades of experience in soldering materials and chemical formulations—and he’s built a company committed to performance, consistency, and innovation. Earlier this year, Ward and his company were honored with the prestigious King’s Award for Enterprise in International Trade, recognizing their exceptional export growth. That recognition earned him an invitation to Windsor Castle, where he had the distinct honor of meeting King Charles III. Today, we’ll explore the evolving world of soldering materials—from the realities behind “no-clean” flux, to reliability challenges in harsh environments, to innovations in solder chemistry that support today’s miniaturized and mission-critical electronics. Whether you're on the production floor, in the design lab, or managing quality and reliability, this is a conversation that brings valuable insight into the materials behind the mission.

Margaret Upshur is CEO of Mobius Materials, a global online marketplace for excess electronic components. Before founding Mobius, she was senior director of operations at Particle, which supplies application infrastructure for deploying software and models on computing or IoT devices. And while in college she cofounded a company that made a hand-held device to detect the alcohol content of liquids. Noting some $15 billion or more is wasted each year in unused or obsoleted components, Upshur founded Mobius to provide a platform for trading excess inventory much in the way Wall Street brokers trade stocks.  We discuss her model for a sustainable, resilient supply chain; why the buyers and sellers on the Mobius platform can trade anonymously; as well as the PCB Community Meetup featuring a panel on the Ever-Changing Procurement Environment Mobius is sponsoring at PCB West on Oct. 1.

Chapters: 00:00 Introduction & Episode Overview 02:12 Meet Victoria Rawinsky: Expertise & Industry Impact 05:09 Social Media Challenge & Making Science Accessible 09:09 Humidity in Electronics: The Science & Risks 15:12 Types of Humidity & Effects on Materials 20:04 Manufacturing Shortcuts & Hidden Failures 25:30 Real-World Reliability Failures & Case Studies 31:02 Miniaturization, Board Layout & ECM 35:52 Best Practices: Cleanliness, Coatings & Moisture Mitigation 41:32 Material Choices, Standards & the Invisible Risks 45:51 The Smell Test: Practical Tips & Final Thoughts 47:16 Upcoming Events & Community Involvement 48:18 Outro & How to Stay Connected  

Stephen Chavez is principal technical product marketing manager with Siemens, but he’s best known for his three decades as a printed circuit designer and instructor. He’s a regular contributor to various industry publications and host of the Printed Circuit Podcast. He also coauthored and teaches the PCEA Training Certified Printed Circuit Designer curriculum, and is chairman of PCEA. He talks about some of the issues designers are running into, his upcoming presentations at PCB West, and the design-related programs at the college level, where he has been teaching of late.  

Mike Konrad is joined by two of the most respected names in the electronics manufacturing industry, Phil Zarrow and Jim Hall. Together, they bring decades of hands-on experience and unparalleled insight into the challenges and solutions within our field. Hall and Zarrow are the driving forces behind ITM Consulting, where they help manufacturers around the world improve processes, solve complex problems, and build more reliable products.  Whether it’s soldering, cleaning, reflow profiling, process control, or failure analysis, these two have seen it all, fixed it all, and taught it all. In this episode, we tackle some of the most pressing issues facing the industry today, from the challenges of miniaturization, the reality of voiding, to the rise of electronics deployed into harsh environments, to IPC standards, and the role of process control in ensuring long-term reliability. Whether you're a process engineer, a quality manager, or simply passionate about electronics manufacturing, this is a conversation you won’t want to miss.