Reliability Matters

Since 2018, Reliability Matters has been building a knowledge vault, capturing the wisdom of industry experts for engineers everywhere. In this special year-end episode, we celebrate the journey, the growth, and the community that made it possible.

Today, we’re continuing our dive into the world of contract manufacturing—a vital piece of the electronics ecosystem.Joining me are two industry leaders who know this space inside and out. First, we have Daniel Stanphill, SMT Process Engineer at Aurora Boardworks, and alongside him, Sean Kincaid, President of K & F Electronics. Both Daniel and Sean represent companies that provide contract manufacturing services to a wide range of customers, helping turn design concepts into dependable, production-ready circuit assemblies.In this conversation, we’ll explore what makes for a successful relationship between contract manufacturers and their customers. We’ll talk about the types of customers they look for, the challenges they face in today’s manufacturing environment, and the common mistakes that can derail a project if not addressed early on. Most importantly, we’ll dig into best practices that can help customers and manufacturers work together more effectively.You may recognize Daniel and Sean. In addition to their day jobs, Daniel and Sean, along with Elias Malfavon Jr. are also co-hosts of the d-code podcast, where they share candid conversations and insights from across the electronics industry. We’ll hear what inspired them to launch the show and how it ties into their mission of building stronger connections in this field.So whether you’re an engineer, a buyer, or anyone working with contract manufacturers, this episode is packed with advice to help you navigate the process with confidence. Daniel is an SMT Process Engineer at:Aurora Boardworkshttps://auroraboardworks.comSean is President of:K & F Electronicshttps://www.circuitboards.com

The next two episodes will be all about contract manufacturing, an area that can make or break the reliability and success of a product. My guest on this episode is Raymond Novara, founder and owner of East End Assemblies, a U.S.-based contract manufacturer recognized for its focus on quality, customer service, and compliance with AS9100 and IPC standards.During our conversation, I’ll be asking Raymond some 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.Raymond Novara's Company:East End Assemblieshttps://eastendassemblies.com

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 me 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 degree in materials science and engineering and in mechanical engineering and a Bachelor’s degree in metallurgical physical chemistry he’s also the co-inventor of Durafuse, a groundbreaking 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.Indium's Website:https://www.indium.comDurafuse ®:https://www.indium.com/products/alloys/solder-alloys/durafuse-lt/

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 me is Ross Berntson, President and CEO of Indium Corporation. Ross has been with Indium Corporation 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, Ross 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.Ross 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.Indium Corporation:https://www.indium.comThe book Ross recommended:Range: Why Generalists Triumph in a Specialized World Paperback By David Epsteinhttps://tinyurl.com/3tjvj34n

This is the second of four episodes on the subject of soldering materials.In today’s episode, continuing the subject of soldering materials, diving deep into the science, strategy, and subtleties behind one of the most foundational elements of electronic assembly: soldering materials. Joining me are two experts from KOKI Solder—Shantanu Joshi, Head of Customer Solutions and Operational Excellence, and Greg Starrett, General Manager of North American Operations. Together, they bring decades of experience in solder chemistry, process engineering, and real-world reliability. We’ll explore how soldering materials influence long-term performance, how material and process decisions interact, and what assemblers should consider when aiming for high-reliability outcomes.From surface finishes and flux residues to void mitigation and future trends in solder formulation, this episode offers practical insights that go well beyond the datasheet.So whether you’re on the factory floor, in the lab, or managing quality and reliability at scale—this conversation is for you.Shantanu JoshiHead of Customer Solutionsshantanu@kokiamerica.comGreg StarrettNational Sales Managergreg@kokiamerica.com

This episode is all about SMTAI, surface mount Technology International, taking place OCTOBER 19 - 23, 2025 at the DONALD E. STEPHENS CONVENTION CENTER in ROSEMONT, ILLINOIS. SMTA International is the premier gathering for innovation and collaboration in electronics assembly, surface mount technology, and advanced manufacturing.This year, SMTAI is more than just a conference and expo. It’s an opportunity for experts, newcomers, industry leaders, and rising professionals to come together, exchange ideas, showcase breakthroughs, and shape the future of electronics manufacturing. Over several days, you’ll see deep-technical sessions, the latest research, hands-on exhibits, and, co-located with the assembly show, you can expect a bustling expo floor where solution providers and attendees connect on everything from process optimization to next-generation materials.To talk more about the technical conference, I’ve invited members of the conference committee to share some highlights of the conference.Tony Lentz from FCT AssemblyGayle Towell from Aim SolderTom Rovere from Lockheed MartinMaurice Dore from ValeoKelly Flanagan from RockwellAnd, although not a member of the Technical Committee but a member of the SMTA Global Board of Directors and Chair of the Students and Young Professionals committee, Dr. Adam Klett of Kyzen Corporation.More information on SMTAI is available here:https://www.smtai.org

This is the first of four episodes on the subject of soldering materials.In this episode, I’m joined by Chris Ward, founder and Managing Director of Solderking Assembly Materials Limited, a UK-based manufacturer of solders and chemical consumables for electronic, electrical, and engineered assemblies.Chris 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, Chris 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.SolderKing:https://solderking.com

On this episode of Reliability Matters, we’re diving into a deceptively simple but incredibly important topic, humidity, and the massive impact it can have on electronic assembly reliability.Joining me is Viktoria Rawinski, a seasoned expert in materials science and reliability engineering, whose career spans decades of hands-on experience in failure analysis, process optimization, and design-for-reliability practices. Viktoria is not only a respected voice in the industry, but also a passionate educator, known for breaking down complex technical issues into actionable insights.In her two-part LinkedIn technical series, “Humidity – A Small Cause with a Huge Effect,” Viktoria explores how environmental moisture, often overlooked or underestimated, can trigger serious failure mechanisms in circuit assemblies, especially as devices become smaller and more complex. From solder mask absorption to electrochemical migration, we'll unpack the hidden risks that can jeopardize product performance and long-term reliability.Whether you're in design, manufacturing, or quality assurance, this is a conversation you won’t want to miss.Viktoria's Websitewww.rawinski.de

Today, I’m 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.Jim and Phil 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.ITM Consulting:https://itmconsulting.com