Reliability Matters

This episode is a little different in two ways. First, I didn’t record it in my studio. I recorded it at the SMTA Pan Pacific strategic Electronics symposium, affectionately known as PanPac, in beautiful Maui Hawaii.Each year, I record a Reliability Matters podcast at PanPac. Normally, the format of the show is I ask questions, and my guests provide answers. On this episode however, I decided to let my guest do all of the talking. The theme of this episode is Electronics: Down Memory Lane and a Vision for the Future. My three guests on this episode will share their view of the history of electronics from three different perspectives. My guests are Dr. Ron Lasky from Dartmouth College, Dr John Evans, and Dr. Tom Duval, both from Auburn University. They’ll share their perspectives on the history of the electronics industry in presentation format.

Today, we’re putting the spotlight on a critical component in surface mount technology, the stencil. These precision-engineered tools are the unsung heroes of electronic assembly, playing a pivotal role in ensuring accurate solder paste deposition and, ultimately, the reliability of your circuit assemblies.It's been long said that reliability begins at the solder print, and the print begins with the stencil.Joining us today is Elias Malfavon Jr, President of Metal Etch Services, Inc. a stencil manufacturer operating in San Marcos California. Metal edge services was founded 20 years ago in 2005. We’ll explore the fascinating journey of stencil production, from design and material selection to the advanced laser cutting technologies that ensure microscopic precision. We’ll also discuss the latest innovations in stencil technology, their impact on modern assembly processes, and how the industry is evolving to meet the challenges of ultra-high-density interconnects and miniaturization.So, sit back, relax, and let’s uncover the critical role of SMT stencils in today’s electronics manufacturing landscape.Elias Malfavon Jr's Contact Info:eliasjr@metaletchservices.comMetal Etch Services, Inc.https://metaletchservices.comThe D-Code Podcasthttps://www.youtube.com/@The-D-Code

Today, we're tackling a topic that has become increasingly vital in recent years: supply chain management. With global supply chains recently under immense pressure from disruptions, shortages, and growing complexity, the need for smarter, more efficient solutions has never been greater. And what better way to explore this than by discussing the cutting-edge role of AI-powered supply chain management software.My guest today is Sebastian Schaal, the founder and CEO of Luminovo, a company at the forefront of transforming how supply chains are managed in the electronics industry. Sebastian Schaal is the founder of Luminovo, a leading software provider revolutionizing the electronics supply chain. He holds two masters degrees—one in Electrical and Computer Engineering from the Technical University of Munich and another from Stanford University, where he was a Fulbright scholar focusing on Management and Computer Science. Before founding Luminovo, Sebastian gained diverse industry experience, working on AI algorithms for signal processing and computer vision at Intel and robotics companies NavVis and Magazino. Additionally, he served as a consultant at McKinsey, advising on data strategy.Sebastian and his team are leveraging artificial intelligence to streamline processes, enhance collaboration, and future-proof supply chain operations. In this episode, we'll explore how AI is reshaping supply chain management, the unique challenges facing the electronics industry, and what companies can do to stay ahead in an ever-changing global landscape. This conversation is packed with insights you won't want to miss. So, sit back, relax, and get ready to learn about the innovations that are revolutionizing supply chains worldwide. Luminovohttps://luminovo.comChapters:00:00:00 The Role of AI in Revolutionizing Supply Chain Management00:02:30 Innovation in Supply Chain Management: Origins and Vision00:04:56 The Unsung Heroes of the Electronics Supply Chain  00:07:25 The Impact of Supply Chain Challenges on Business Growth00:10:06 Challenges in Electronics Supply Chain Management00:12:28 Navigating the Complexities of Supply Chain Management  00:14:51 AI and Machine Learning in Modern Supply Chain Management  00:17:31 Enhancing Supply Chain Resilience with Digitalization and Collaboration00:20:03 Enhancing Collaboration with Digital Tools00:22:26 Automating Processes for Efficiency and Cost Optimization00:24:55 Choosing the Right Supply Chain Software: Industry-Agnostic Vs. Specific Vendors00:27:24 Advantages of Vertical Solutions in the Electronics Industry00:30:06 Challenges in Semiconductor Manufacturing and Supply Chain  00:32:35 Evolution of AI: From Engines to Intelligent Agents00:34:57 Transforming Manufacturing with Cloud and AI00:37:26 Overcoming Resistance to Digital Transformation in Supply Chains00:40:03 Overcoming Fragmented Data in Supply Chains00:42:36 Implementing New Systems and Avoiding Pitfalls00:45:08 Key Questions for Supplier Data Integration00:47:32 Common Mistakes in Selecting Supply Chain Management Systems00:50:04 Enhancing Supply Chain Integration and Automation00:52:23 Building a Global Supply Chain Network  00:57:19 Conclusion and Upcoming Podcast Schedule

Today we’re diving into a critical yet sometimes overlooked component that powers so many of the devices we rely on: batteries. Batteries are the heartbeat of countless electronic products, from medical devices and electric vehicles to consumer gadgets and industrial systems. Choosing the right battery is not a one-size-fits-all decision. It requires a keen understanding of the application, performance needs, and environmental demands. The right selection can make the difference between a product that excels in reliability and one that, quite literally, fails to deliver.  But there’s more to batteries than just selecting the right chemistry or capacity. Safety is paramount. Poor battery selection, design, or management can lead to performance issues, overheating, or catastrophic failures. As we’ve all seen in headlines, battery malfunctions can result in recalls, damage to brand reputation, or, worse, safety hazards for users.  To shed light on this vital topic, we’re joined by an expert in the field of battery technology. Alex Norman is a Battery Management System Designer at Pro Technologies, a well-established and trusted custom battery pack manufacturer, providing engineering capabilities from concept through production. Their leading edge manufacturing facility and headquarters is based in Pilot Mountain, North Carolina. Alex has deep experience in Printed Circuit Board Design, Product Development, Battery Management Systems and more. Alex is also a content creator, focusing mostly on electronics, battery, and BMS content available on his LinkedIn page and YouTube channel.Today, we’re going to explore how to choose the right battery for your assembly, best practices for integration, and how to mitigate potential safety risks.  So, if you care about keeping your products powered, reliable, and safe, don’t bolt just yet – this podcast on batteries is positively charged with insights! Stick around and top off your battery knowledge!Alex's Contact Info:Alex Normananorman@eetengineer.comProTechnologies, Inc.http://protechnologies.comAlex's YouTube Channel:https://www.youtube.com/@eetengineerChapters:00:00:00 Choosing the Right Battery for Electronic Assemblies00:02:44 Exploring Battery Technology and Safety Concerns00:05:21 Starting a YouTube Channel: Journey and Growth00:07:55 Performance and Safety: Alkaline vs. Lithium-Based Batteries00:10:28 The Future of Sodium-Ion Batteries vs. Lithium-Ion00:13:12 Causes of Samsung Phone Battery Fires00:16:01 Advancements in Solid State Battery Technology00:18:44 Dangers of Swollen Lithium Batteries and Battery Safety00:21:19 Battery Charging Myths and Optimization Techniques00:24:04 Importance of Battery Management Systems (BMS)00:26:51 Primary vs. Secondary Batteries Explained00:29:28 Comparing Performance: Alkaline vs Rechargeable Batteries00:32:11 Impact of Temperature on Battery Performance00:34:51 Optimizing Battery Performance in Extreme Cold00:37:28 Lead Acid vs. Lithium Iron Phosphate: Battery Safety and Advancements00:39:56 Optimizing Battery Performance in Electric Cars00:42:36 Advanced Lithium Iron Phosphate Cells  00:45:24 Battery Regulations Impact and Safety Standards00:48:05 Battery Safety and Standards in Consumer Electronics00:50:49 Quality and Safety in Consumer Vs. Industrial Battery Cells00:53:25 The Importance of Proper Battery Recycling00:56:05 Lithium Iron Phosphate vs. Nickel Metal Hydride Batteries00:59:51 Humor and Technology: Creating Engaging Content01:01:10 Get Involved with Reliability Matters Podcast

On this episode, we’ll dive into the world of electronics testing with an expert within the electronics testing industry, Robert Boguski,  President and Owner of Datest. Robert brings 44 years of experience in the design, fabrication, assembly, and testing of printed circuit boards (PCBs) and electronic systems. Under his leadership, Datest has become a premier provider of advanced, integrated PCBA testing and inspection services, serving both contract manufacturers and original equipment manufacturers since its founding in 1984. Robert's extensive background includes active participation in industry associations such as APICS, SMTA, and IPC, reflecting his commitment to advancing the field. He is also a columnist for Circuits Assembly Magazine, where he shares his insights on industry trends and challenges.  In this episode, we'll explore Robert's journey in the electronics manufacturing industry, the evolution of testing technologies, and his perspectives on the future of electronics testing. Join us as we gain valuable insights from a leader whose career has been dedicated to excellence in electronic testing and manufacturing.Robert's Info:Robert Boguskirboguski@datest.comDatesthttp://www.datest.com

Today, we’re exploring a transformative topic: AI-based inspection technologies.  Artificial intelligence is revolutionizing how we detect, analyze, and address defects in the electronics assembly process, combining precision with unparalleled speed to unlock new possibilities for efficiency and reliability.Our guest today is a leading innovator in this field. Priyansha Bagaria is the founder and CEO of Loopr AI, a company at the forefront of AI-powered solutions for manufacturing inspection. Priyansha holds an MBA in International business and Global management, a bachelors of engineering degree in computer Science, and she held a fellowship in data science at Cornell University.Her academic background, coupled with her entrepreneurial spirit, has positioned her as a trailblazer in applying AI to manufacturing processes.In this episode, we’ll explore the advancements Loopr AI is spearheading, how AI inspection technologies are reshaping traditional methods, and the tangible benefits AI offers to manufacturers striving for excellence. Loopr AI Website:https://www.loopr.ai

Today, we’re diving into one of the most transformative innovations of our time: electric vehicles and the vast infrastructure needed to support their growth. Joining us is Brian O’Leary, Global Head of of e-Mobility & Infrastructure at Indium Corporation, a leading expert with deep insights into the electronic assembly industry and its critical role in the EV revolution.As electric vehicles continue to redefine the future of transportation, the reliability and scalability of the infrastructure that powers them—particularly public EV charging stations—have become pivotal challenges. The electronic assembly industry is at the heart of these systems, from the semiconductors enabling fast charging to the sensors ensuring safe and efficient operation. However, with nearly 26% of public EV charging stations estimated to be non-functional at any given time, reliability remains a significant hurdle.This episode will explore the major reliability issues plaguing public EV charging stations, including power instability, component failures, and environmental challenges.How innovations in electronics design and assembly can address these challenges, from improving thermal management to leveraging advanced materials like those developed by soldering materials manufacturers.The exciting opportunities for the electronics industry to lead the charge in building a more resilient, reliable, and efficient EV infrastructure.Brian O’Leary brings a wealth of knowledge on how advanced materials, smart assembly techniques, and innovative designs can solve these pressing issues and accelerate the adoption of electric vehicles. Together, we’ll review the technical challenges, explore solutions, and look ahead to the bright future of electric mobility.Brian O’Leary's Contact Info:boleary@indium.comhttps://www.indium.com

Today we’re celebrating the end of another incredible year. This isn’t just any episode—it’s a time to reflect on the journey we’ve been on together, highlight some milestones, and share a heartfelt thank you to everyone who has made this podcast such a success. Can you believe it? Reliability Matters has now released 159 episodes! It feels like just yesterday we started this podcast with the mission to explore how industry experts and their knowledge contribute to the reliability of electronics. And here we are—growing, learning, and making a real impact in our field.But here’s what blows me away the most: over 85,000 downloads. That’s not just a number—it’s a testament to you, our amazing audience. Whether you’re listening in your car or on your morning jog, or watching this on our YouTube channel, you’ve made this podcast part of your journey. And for that, I’m deeply grateful.This year alone, we’ve covered some fascinating topics. From ultra-high-density interconnects to post-reflow inspection, from thermal profiling to cutting-edge coating materials—we’ve explored it all. Along the way, I’ve had the privilege of sitting down with some of the brightest minds in the electronics industry.  Each guest has brought their unique insights, helping us all better understand the intricate science and art behind building reliable electronics.To my incredible guests—thank you. Your willingness to share your expertise, stories, and even a few laughs has been the lifeblood of this podcast. Every episode is a reflection of your generosity and brilliance.I also want to give a shout-out to you—yes, you. Whether you’re a long-time listener or you just discovered us this year, you’re the reason I do this.  The messages, the comments, the emails—it’s all so inspiring. When you tell me how a particular episode helped solve a problem, spark a new idea, or simply make your day better, it reminds me why Reliability Matters matters.As we wrap up the year, I’m reminded of something I say often on this show: reliability isn’t just a goal; it’s a journey. It’s a series of choices, processes, and innovations that, together, ensure the technology we rely on lives up to its promise. And this podcast? It’s a part of that journey. It’s a space where we can learn together, challenge assumptions, and stay ahead of the curve in an ever-evolving industry.Mike Konrad's Contact Info:mike@mikekonrad.comhttps://www.reliabilitymatterspodcast.com 

Today, I’m excited to introduce the hosts of the D-Code podcast, a dynamic trio of young professionals making waves in the electronics manufacturing industry. With experience rooted in contract manufacturing and stencil fabrication for electronic assemblies, they bring a fresh perspective to the table. Although they’re at the start of their podcasting journey, D-Code has already begun to attract attention, tackling industry insights with a unique lens that up-and-coming voices can uniquely offer. My guests today are Daniel Stanphill, SMT Process Engineer at Aurora Boardworks, a contract assembler located in Aurora, Nebraska, Sean Kincaid, President of K & F Electronics, located in Fraser Michigan, also a contract manufacturer, and Elias Malfavon, President of Metal Etch Services, a SMT stencil fabricator located in San Marcos California.I’ll ask them about their experiences, challenges, and how they’re setting out to decode the world of electronics manufacturing.Contact Information:The D-Code Podcasthttps://www.youtube.com/@The-D-CodeDaniel StanphillAurora Boardworksdaniel.stanphill@auroraboardworks.comhttps://auroraboardworks.comSean KincaidK & F Electronicssean@the-d-code.comhttps://www.circuitboards.comElias Malfavon Metal Etch Serviceselias@the-d-code.comhttps://metaletchservices.com

On today’s episode, we’ll be exploring the critical steps to avoid contamination on circuit assemblies during the rework process with our expert guest, Gayle Towell. Gayle is the Content Marketing Specialist at AIM Solder, a leading global manufacturer of solder assembly materials for the electronics industry. She holds master's degrees in both mathematics and physics from the University of Oregon and has nearly two decades of experience in higher education, technical writing, and creative writing. In her role at AIM Solder, Gayle is instrumental in producing technical and research-based materials, while also collaborating with industry partners on various projects.  She has contributed articles to industry publications, such as the Printed Circuit Engineering Association Magazine, where she discusses topics like solder paste powder sizes and mixing methods. Gayle has also participated in industry events, including the SMTA International conference, where she shared her expertise in sessions covering soldering technologies and solder paste advancements. Additionally, she has appeared on podcasts discussing the development of new solder products. Her extensive background in technical communication and her role at AIM Solder highlight her significant contributions to the electronics manufacturing industry, and today she’ll be sharing her insights from a recent technical article "What's on Your Rework Bench."In this discussion, we’ll review the rework station and the essential practices that can make or break circuit reliability. Gayle will walk us through the common pitfalls she’s seen—from the dangers of unapproved fluxes to mismatched cleaning solvents—and explain how these mistakes lead to long-term failures in the field. She’ll also share practical advice on maintaining a contamination-free bench, the importance of selecting compatible chemistries, and why regular audits and operator education are key to preventing unintended residues and contaminants.Gayle will help us prevent one problem, rework, while not creating another, contamination.Gayle's Contact InformationGayle Towellgtowell@aimsolder.comhttps://www.aimsolder.com