Reliability Matters

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

Joseph Fjelstad, founder of Verdant Electronics and a renowned expert in electronics interconnection, shares his insights on flexible circuits. He discusses how these innovative circuits have revolutionized design, especially in compact applications like wearables and medical devices. Fjelstad highlights their lightweight, durable nature while addressing manufacturing complexities. He also delves into the creativity born from naivety and the historical evolution of these circuits, making a compelling case for collaboration in advancing the technology.

Today, I’m in Rosemont Illinois at SMTAI, Surface Mount Technology International. I’m in the Ultra-HDI Pavilion on the trade show floor. And what are we going to talk about here in the Ultra-HDI pavilion? Ultra high density interconnects, of course.As the demand for smaller, faster, and more powerful devices grows, the need for innovative solutions in circuit design has never been greater. UHDI's represent a significant leap forward, allowing for more connections in a smaller space, pushing the boundaries of what's possible in electronic assemblies.But what exactly are UHDI's? Essentially, they refer to circuit boards with incredibly fine pitch interconnects, enabling higher functionality and complexity in much smaller form factors. This breakthrough is transforming industries like consumer electronics, aerospace, automotive, and medical devices, where space, weight, and performance are critical factors.In this episode, we’ll explore the advantages UHDI's bring to the table, from increased design flexibility and performance to better thermal management. We'll also discuss how UHDI's are set to impact the assembly process. With tighter tolerances and more intricate layouts, UHDI assemblies will require new approaches to assembly, inspection, and reliability testing.To better explain UHDI technology, we’ve put together a panel of subject matter experts. Tara Dunn, Director of Training and Education at the Surface Mount Technology Association (SMTA), will moderate a panel discussion with other subject matter experts.In addition to Tara, our other experts are Anaya Vardya CEO of American Standard Circuits, Chrys Shea from Shea Engineering Services, Michael Sivigny, owner and General Manager of CeTaQ Americas, Oren Manor, Op-Center Core Program Business Director at Siemens Digital Industries Software, and Anaya Vardya from American Standard Circuits.Ultra-HDI is here! And if you haven’t seen it on your assembly line yet, it’s coming, so stay tuned as we unpack the future of Ultra High Density Interconnects and what it means for the next generation of technology.

Mark Waterman, the Electronics division manager at ECD and a thermal profiling expert, dives deep into the importance of thermal profiling in manufacturing high-reliability circuit assemblies. He discusses how temperature impacts solder joint integrity and shares best practices to avoid common mistakes. Mark highlights cutting-edge advancements in thermal profiling technology, including real-time data collection and the significance of proper thermocouple use. With his experience, he sheds light on the challenges faced in this competitive industry and the balance between science and art in optimizing processes.

If you're part of the electronics landscape, you've likely encountered the role contract manufacturers play — and it's a critical one. These specialized partners bridge the gap between design innovation and full-scale production, bringing efficiency, expertise, and flexibility to the table.As companies seek to meet growing demand for advanced electronic products, contract manufacturers are increasingly relied upon to provide cost-effective, high-quality assembly services. Whether it's managing supply chains, ensuring compliance with industry standards, or accelerating time to market, their contributions have become indispensable. In today's episode, we'll explore how contract manufacturing works, why it's so vital, and what trends are shaping the future of this essential industry.My guest today is Adrian Leal. Adrian serves as the USA Business Development Manager for Teltonika EMS and is the President of the Houston SMTA Chapter. With over 30 years of experience in the manufacturing industry, he has worked extensively as both an end user and a service provider. Throughout his career, he has held diverse roles including process engineer, manufacturing engineer, quality engineer, field engineer, and sales engineer.In 2003, Adrian became the first engineer from the oil and gas industry to earn the prestigious Process Engineer certification from the SMTA. From 2006 to 2015, he voluntarily took on the role of ESD Subject Matter Expert for SLB, where he developed an internal ESD program that remains in use today.If you’re in Texas, you may know Adrian from his involvement in Cup of Joey networking events.I’ll talk with Adrian about his transition from an OEM to a contract manufacturer and his recommendations on how to choose the most appropriate contract manufacturer for your needs.Adrian’s contact information:Adrian Lealadrian.leal@teltonika-iot.comhttps://teltonika-iot-group.com