<p id="isPasted">When constructing a footprint for BGA-style components, choosing between solder mask-defined (SMD) and non-solder mask-defined (NSMD) pads is imperative. The correct pad design can mitigate many manufacturing problems and reduce time spent analyzing failures. This article outlines a few simple principles to guide you in creating the right footprints for BGA components.</p><h2><p>Understanding SMD and NSMD Pads</p></h2><p>There are two basic forms of pads implemented for BGA footprints. One is the Solder Mask Defined pad (SMD) and the other, is the Non-Solder Mask Defined pad (NSMD). Let’s take a look at these two types and discuss how to use them in your BGA designs.</p><p>In electronics, "SMD" can also refer to a surface mount device, but in this case we are using it in a different context.</p><h3>Define SMD (Solder Mask Defined):</h3><ul><li>Definition: In SMD pads, a layer of solder mask covers a portion of the underlying copper pad, creating a smaller solder mask opening.</li><li>Benefits:<ul><li>Enables precise soldering due to the reduced copper pad size.</li><li>Enhances the overall reliability and performance of the final device.</li><li>The solder mask opening acts as a guide during BGA ball placement for soldering</li></ul></li></ul><h3>Define NSMD (Non-Solder Mask Defined):</h3><ul><li>Definition: NSMD pads differ by leaving a gap between the copper pad and the solder mask, exposing the entire pad.</li><li>Benefits:<ul><li>Offers superior solder adhesion due to full pad contact with the solder ball.</li><li>Allows for a smaller pad size, simplifying trace routing, especially for high-density BGAs.</li></ul></li></ul><h2><p>Solder Mask Defined BGA Pads (SMD)</p></h2><p><a href="https://macrofab.com/blog/bga-pad-creation-smd-nsmd/#" title="click to enlarge" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731437204486-1731437204486.png" alt="SMD Style BGA Pad" class="fr-fic fr-dii"></a></p><p>SMD Style BGA Pad</p><p>In SMD pads, the solder mask aperture is outlined to be smaller than the diameter of the pad that it encompasses. This approach limits the size of the copper pad that the component is soldered to, providing two key benefits.</p><ul><li><strong>Enhanced Pad Security:</strong> The solder mask overlay strengthens the connection between the pad and the circuit board. This helps prevent the pad from lifting off (delamination) due to thermal or mechanical stress that the PCB might experience during operation or manufacturing.</li><li><strong>Solder Ball Alignment:</strong> The opening in the solder mask acts as a guide, ensuring proper BGA ball placement during the soldering process. This contributes to precise soldering and overall joint integrity.</li></ul><p>In the top-down view, we can see that the solder mask is specified to cover a portion of the copper pad underneath. Defining pads this way creates two distinct advantages. First, the overlapping mask helps prevent the pads from lifting off of the PCB due to thermal or mechanical stress. Second, the opening in the mask creates a channel for each ball on the BGA to align with while the component progresses through the soldering process.</p><p>The copper layer of an SMD BGA pad typically has a diameter equal to the diameter of the pad on the BGA itself. To create the SMD overlay, a reduction of 20 percent is typically used.</p><h2><p>NSMD Pads for BGA Components</p></h2><p><a href="https://macrofab.com/blog/bga-pad-creation-smd-nsmd/#" title="click to enlarge" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731437204561-1731437204561.png" alt="NSMD Style BGA Pad" class="fr-fic fr-dii"></a></p><p>NSMD Style BGA Pad</p><p>In contrast, NSMD pads are structured differently from SMD pads. With NSMD pads, the solder mask is designed to not interact with the copper pad, leaving a gap between the pad's edge and the solder mask. Instead, the mask is created such that a gap is created between the edge of the pad and the solder mask. The following image shows a top and cross-section view of an NSMD-style pad.</p><p>In this method, the size of the copper landing pad is not defined by the mask layer, but only by the diameter of the copper pad itself. NSMD pads can be smaller than the diameter of the solder ball. Typically, this reduction in pad size is 20% smaller than the ball diameter. Since the pad size is reduced with this approach, the additional room between adjacent pads allows for easier trace routing. This can almost become a necessity when routing high-density, fine-pitch BGA chips.</p><p>By allowing for a smaller pad size, NSMD pads facilitate easier trace routing - an almost necessary feature when dealing with high-density, fine-pitch BGA chips. However, NSMD pads are prone to delamination from the PCB under mechanical and thermal stress. Following standard manufacturing and handling practices should prevent this from occurring.</p><h2><p>Solderability of SMD vs NSMD BGA Pads</p></h2><p><a href="https://macrofab.com/blog/bga-pad-creation-smd-nsmd/#" title="click to enlarge" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731437204354-1731437204354.png" alt="Solder Adherence of SMD and NSMD BGA Pads" class="fr-fic fr-dii"></a></p><p>Solder Adherence of SMD and NSMD BGA Pads</p><p>The following images show examples (highly exaggerated) of how a solder ball adheres to each style of pad:</p><p><br></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731437204638-1731437204638.png" alt="Isometric view of BGA Pad Styles" class="fr-fic fr-dii"></p><p>Isometric view of BGA Pad Styles</p><p>With the entire pad exposed, NSMD pads tend to have better solder adhesion than SMD pads. The solder ball is able to make a connection to the entire NSMD pad instead of the mask-defined portion of SMD pads.</p><p><br></p><h2><p>SMD vs NSMD: Which BGA Pad Style to Use</p></h2><p>It is important to note that component manufacturers typically provide recommended footprints in the datasheets for their components. When these footprints are available, it’s certainly advisable to use them.</p><p>In general, use the NSMD pad style wherever possible due to its improved solderability and pad accuracy. <a href="https://help.macrofab.com/knowledge/what-are-macrofabs-assembly-capabilities/" target="_blank">Visit our Knowledge Base for more information.</a></p><p><br></p><h4 id="isPasted">Ready to start your next project?</h4><p><a href="https://factory.macrofab.com/quick_quote?utm_source=direct&utm_medium=none" target="_blank">Get an instant quote now</a></p><section><h5><br></h5></section>

Choosing between solder-mask-defined and non-solder-mask-defined pads is an imperative when constructing footprints for BGA-style components. 

SMD vs NSMD: Best Practices for BGA Pad Creation

<p data-pm-slice="1 1 []" id="isPasted">Finishing techniques can enhance the surface quality, durability, and appearance of metal 3D printed parts, making them suitable for a wide range of applications. Here’s a look at some of the key finishing technologies used in metal additive manufacturing.</p><p><br></p><p><strong>Air Blasting</strong></p><p>Air blasting is a versatile finishing process that involves accelerating blasting materials through a nozzle to treat the surface of a metal part. This technique is commonly used to clean surfaces, remove residual powder from the 3D printing process, and alter surface roughness. By reshaping or removing material, compressed air blasting can enhance the texture of a part, making it smoother or more consistent. It is particularly useful for preparing parts for further finishing processes or improving their mechanical properties.</p><p><br></p><p><strong>Blackening</strong></p><p>Blackening is a specialized finishing technique primarily used on iron and steel components. The process involves creating a thin protective layer of black oxide on the surface of the metal, which helps to reduce rust and improve friction properties. Blackening not only enhances the aesthetic appeal of a part by giving it a darker, matte finish but also preserves its dimensions, making it a popular choice for parts that require both protection and precision. This technique is commonly used in firearms, tools, and other iron-based products.</p><p><br></p><p><strong>Gold plating</strong></p><p>Gold plating is the process of covering a metal surface with a layer of gold through electroplating. In this technique, the metal object is submerged in a gold electrolyte solution, and an electric current is applied to deposit a thin, uniform layer of gold onto the surface. Gilding is often used for decorative purposes, adding a luxurious appearance to metal parts. Additionally, it can provide a layer of corrosion resistance, making it a practical as well as an aesthetically pleasing finish for high-end applications.</p><p><br></p><p><strong>Anodizing</strong></p><p>Anodizing is a finishing process that creates a protective oxide layer on metal surfaces by converting the existing material rather than adding an external layer. This process involves submerging the part in an electrolyte solution and applying an electric current, which forms a thin, compact oxide layer on the surface. The thickness of this layer can be varied, resulting in different colors, from deep blacks to vibrant blues and reds. Anodizing is commonly used on aluminum parts to enhance corrosion resistance, improve wear resistance, and achieve a decorative finish.</p><p><br></p><p><strong>Nickel Plating</strong></p><p>Nickel plating involves applying a layer of pure nickel to a metal surface using electric currents. This process is widely used to protect metals such as iron and steel from corrosion while also enhancing their appearance. Nickel plating can be applied in varying thicknesses, making it suitable for both decorative applications and industrial uses where a durable, corrosion-resistant coating is needed. It is also commonly used as a base layer for other finishes or to improve solderability in electronic components.</p><p><br></p><p><strong>Polishing</strong></p><p>Polishing is a finishing process that smooths and refines the surface of a metal part through mechanical grinding and the application of polishing compounds. This process can remove material, round sharp edges, and fill in surface pores, resulting in a smooth, glossy finish that reflects light evenly. Polishing is often used to reduce friction on mechanical parts, enhance their aesthetic appeal, and prepare surfaces for further treatments such as plating or coating. It is an essential step in achieving a high-quality finish on metal 3D printed parts.</p><p><br></p><p>The finishing processes available for metal 3D printed parts offer a wide range of enhancements, from improved durability and corrosion resistance to aesthetic improvements and precise surface alterations. By selecting the appropriate finishing technique, manufacturers can ensure that their metal 3D printed parts meet the highest standards of quality and functionality, suitable for both industrial and consumer applications.</p>

Metal 3D printed Titanium bottle openers - anodized

Metal 3D printing enables the creation of complex and precise components directly from digital designs. To achieve desired aesthetic and functional qualities, the printed parts sometimes require finishing processes.

Enhancing Metal 3D Printed Parts: Finishing Technologies and Techniques

<h3 id="isPasted">Understand the Future of Metal 3D Printing</h3><p>The <strong>Metal 3D Printing Technology Report</strong> is your essential guide to the latest advances, applications, and real-world insights into additive manufacturing with metal. Packed with detailed case studies, &nbsp;practical information, and interviews with industry leaders, this report reveals how metal 3D printing is transforming industries and pushing the boundaries of manufacturing.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730910790125-Mitsubishi+Chemical+Group++Growth+Garage++Open+Innovation+Program+%289%29.png" style="width: 100%px;" class="fr-fic fr-dib"></p><h4>Why Read This Report?</h4><p>The 3D printing industry is evolving quickly and staying updated on cutting-edge manufacturing methods is key. This report not only covers the technical processes behind metal laser powder bed fusion, directed energy deposition, metal extrusion, and binder jetting but also delves into:</p><ul><li><strong>Materials &amp; Post-Processing</strong> – Understand the materials powering metal AM and essential post-processing steps for quality assurance.</li><li><strong>Industry Applications</strong> – See how metal 3D printing is reshaping aerospace, medical, and automotive industries with specific use cases.</li><li><strong>Future Trends</strong> – Get a glimpse of emerging trends, sustainability practices, and the exciting potential of metal AM through case studies and industry insights.&nbsp;</li></ul><p>Whether you're new to metal AM or looking to expand your knowledge, this report offers valuable insights to help you make informed decisions and stay ahead.</p><h4>Get Inspired by Real-World Successes</h4><p>Discover how leading companies are using metal 3D printing to overcome complex manufacturing challenges, streamline production, and unlock new possibilities.</p><h4>Download Now</h4><p><br></p>

<h3 id="isPasted">Understand the Future of Metal 3D Printing</h3><p>The <strong>Metal 3D Printing Technology Report</strong> is your essential guide to the latest advances, applications, and real-world insights into additive manufacturing with metal. Packed with detailed case studies, &nbsp;practical information, and interviews with industry leaders, this report reveals how metal 3D printing is transforming industries and pushing the boundaries of manufacturing.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730910790125-Mitsubishi+Chemical+Group++Growth+Garage++Open+Innovation+Program+%289%29.png" style="width: 100%px;" class="fr-fic fr-dib"></p><h4><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width:100%;max-width:100%;height:950px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span> </iframe></span></h4><h2>Why Read This Report?</h2><p>The 3D printing industry is evolving quickly and staying updated on cutting-edge manufacturing methods is key. This report not only covers the technical processes behind metal laser powder bed fusion, directed energy deposition, metal extrusion, and binder jetting but also delves into:</p><ul><li><strong>Materials &amp; Post-Processing</strong> – Understand the materials powering metal AM and essential post-processing steps for quality assurance.</li><li><strong>Industry Applications</strong> – See how metal 3D printing is reshaping aerospace, medical, and automotive industries with specific use cases.</li><li><strong>Future Trends</strong> – Get a glimpse of emerging trends, sustainability practices, and the exciting potential of metal AM through case studies and industry insights.&nbsp;</li></ul><p>Whether you're new to metal AM or looking to expand your knowledge, this report offers valuable insights to help you make informed decisions and stay ahead.</p><h4>Get Inspired by Real-World Successes</h4><p>Discover how leading companies are using metal 3D printing to overcome complex manufacturing challenges, streamline production, and unlock new possibilities.</p><hr><h2>Report introduction</h2><p dir="ltr">Metal 3D printing, also known as metal additive manufacturing (AM), is a production technology whose origins date back just three decades to 1994, when German company EOS GmbH launched a system based on its Direct Metal Laser Sintering (DMLS) technology<sup>1</sup>. Despite this short history (particularly compared to metal casting, which dates back thousands of years), metal AM has progressed significantly since its earliest iteration, with various new types of processes being developed, new materials and applications being validated, and consistent market growth. This growth—and the continued proliferation of metal AM technologies—is evident by simply looking at the number of metal AM systems sold from year to year. From 2022 to 2023, for instance, the shipment of metal AM systems grew by 24.4% (from 3,049 systems in 2022 to 3,793 systems in 2023). To put it into perspective, just ten years ago, the number of metal AM systems sold was barely over 500<sup>2</sup>.</p><p dir="ltr">Amongst 3D printing users more generally, there has also been an increase in metal AM adoption, from 39% in 2019 to over 90% in 2023<sup>3</sup>. This indicates how the technology has matured and offers a viable production method for a growing number of prototyping and production applications that benefit from the technology’s propensity for complex designs and small-volume production. While challenges to the broader adoption and implementation of metal AM still exist, efforts are being made across the industry to address these barriers through hardware, software, and materials advances as well as industry-wide cooperations.&nbsp;</p><p dir="ltr">This report delves into the metal 3D printing market, whose estimated global value in 2023 was as high as $7.73 billion<sup>4</sup>, for a full spectrum view of the state of the industry. This report includes insights into the leading metal 3D printing processes available on the market today as well as metal AM materials. The report also highlights other vital steps in the AM process chain, including design and post-processing. The fifth chapter of the report covers metal 3D printing applications, with a focus on the three leading adopter industries: aerospace, medical, and automotive. The next two chapters comprise an analysis of the challenges and limitations facing the metal AM industry as well as the key trends that indicate where the future of the industry is headed. The report’s final chapter presents exclusive insights from three companies active in the metal AM space: manufacturing service Xometry, FFF 3D printing company UltiMaker, and software specialist Aibuild.</p><h3>Tess Boissonneault</h3><p>Report Editor-in-Chief</p><p><br></p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width:100%;max-width:100%;height:950px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span> </iframe></span></p><h2>Acknowledgements:</h2><p>Thank you to contributing author Benedict O’Neill.&nbsp;</p><p>Huge gratitude to the experts at UltiMkaer, Xometry and AIBuild with who we consulted with on the texts.&nbsp;</p><h2>References:</h2><p dir="ltr" id="isPasted">1. Singh A, Singh H. Metal additive manufacturing: from history to applications. InInnovations in Additive Manufacturing 2022 Jan 31 (pp. 3-32). Cham: Springer International Publishing.&nbsp;</p><p dir="ltr" id="isPasted">2. Wohlers Report 2024 [Internet]. Wohlers Associates; 2024. Available from: <a href="https://wohlersassociates.com/product/wr2024/">https://wohlersassociates.com/product/wr2024/</a>&nbsp;</p><p dir="ltr" id="isPasted">3. Jabil Unveils Findings of Global Survey on 3D Printing Technology Trends [Internet]. Jabil; July 27, 2023. Available from: <a href="https://investors.jabil.com/news/news-details/2023/Jabil-Unveils-Findings-of-Global-Survey-on-3D-Printing-Technology-Trends/default.aspx">https://investors.jabil.com/news/news-details/2023/Jabil-Unveils-Findings-of-Global-Survey-on-3D-Printing-Technology-Trends/default.aspx</a>&nbsp;</p><p>4. Metal 3D Printing Market Size, Share &amp; Trends Analysis Report By Technology, By Software, By Component (Hardware, Software, and Services), By Application, By Printing Type, By Vertical, By Region, And Segment Forecasts, 2024 - 2030 [Internet]. Grandview Research; 2024. Available from: https://www.grandviewresearch.com/industry-analysis/metal-3d-printing-market</p>

Introduction

An engineer’s guide to understanding the state
of the art in metal 3D Printing

Metal 3D Printing Technology Report

<p data-pm-slice="1 1 []" id="isPasted">Metal 3D printing, once the domain of advanced industrial applications, is now making its way into universities and research institutions, offering students hands-on experience with cutting-edge manufacturing technologies. Here’s how metal 3D printing is transforming education and why it’s an essential tool for preparing the next generation of engineers and designers.</p><p><strong>Metal 3D Printing in Universities: Building Practical Skills and Industry Connections</strong></p><ol><li data-list-indent="1" data-list-type="bulleted"><p><strong>Hands-On Learning with Real-World Applications</strong>: Integrating metal 3D printers into university curricula offers students invaluable practical experience with advanced manufacturing technologies. This hands-on approach not only helps students develop essential engineering and design skills but also enables them to work on real-world projects in collaboration with industry partners. These collaborations provide students with opportunities to apply theoretical knowledge in practical settings, bridging the gap between academia and industry and preparing them for the professional challenges they will encounter after graduation.</p></li><li data-list-indent="1" data-list-type="bulleted"><p><strong>Fostering Innovation through Industry Collaboration</strong>: By working on real projects with companies, students gain direct exposure to the latest industry practices and technologies. This experience is critical for understanding the practical applications of metal 3D printing and helps to cultivate innovative thinking. At the same time, companies benefit from the fresh insights and creative solutions that students bring to the table, making these partnerships mutually beneficial and driving innovation across the board.</p></li></ol><p><br></p><p><strong>Safety First: The Importance of a Safe and User-Friendly System</strong></p><p><strong>Minimized Powder Contact</strong>: Safety is a critical consideration when introducing metal 3D printing into educational settings. Systems like the <a href="https://oneclickmetal.com/boldseries/" target="_blank" rel="noopener noreferrer">One Click Metal printer</a> are designed with safety in mind, featuring a cartridge system that minimizes direct contact with metal powders. This ensures that students can focus on learning without the risks associated with powder handling.</p><p><br></p><p><strong>Research and Advanced Learning</strong></p><p><strong>Versatile and Research-Ready</strong>: The One Click Metal <a href="https://oneclickmetal.com/lab-module/" target="_blank" rel="noopener noreferrer">Lab Module</a> is designed specifically for research purposes, making it an excellent addition to university labs. This build module allows for printing with a variety of materials in small, precise amounts, enabling detailed experimentation and material studies. The Lab Module’s ability to work with different materials in small quantities makes it perfect for research projects that require a high level of precision and material flexibility. Students and researchers can experiment with new materials, optimize printing parameters, and push the boundaries of what’s possible with metal 3D printing.</p><p><br></p><p><strong>Conclusion: A Tool for the Future of Education</strong></p><p>Metal 3D printing is more than just a manufacturing technology—it’s a tool for education and innovation. By bringing metal 3D printers into universities, students are given the opportunity to develop practical skills, engage in real-world projects, and prepare for successful careers in engineering and design. With safe, user-friendly systems, educational institutions can offer a learning experience that equips students with the knowledge and skills they need to lead in the industries of tomorrow.</p>

Metal 3D printing at Trier University of Applied Sciences

As technology continues to advance, the educational sector is evolving to ensure that students are equipped with the skills and knowledge necessary for the future.

The Role of Metal 3D Printing in Education

<div dir="ltr" id="isPasted"><p data-sourcepos="5:1-5:311">Ever wondered what it's like to juggle a variety of small-batch PCB projects, each with its unique set of components and requirements? That's the reality of high-mix, low-volume (HMLV) manufacturing. In this episode of Circuit Break: A MacroFab Podcast, we dive deep into this often-overlooked corner of the electronics industry.</p><p data-sourcepos="7:1-7:393">We'll explore real-world examples of HMLV in action, from companies that order thousands of boards for prototyping to those in specialized industries like aerospace, where even a few units can be considered high-volume. We'll discuss the unique challenges of HMLV, such as managing a diverse range of components, navigating supply chain complexities, and balancing flexibility with efficiency.</p><p data-sourcepos="9:1-9:298">Join us as we break down the key differences between high-volume and HMLV manufacturing, and learn how to identify the right manufacturers for your specific needs. We'll also talk about the importance of a robust inventory management system and the role of specialized equipment in HMLV production.</p><p data-sourcepos="11:1-11:197">Whether you're a seasoned engineer or just starting out, this episode will provide you with valuable insights to help you navigate the complexities of HMLV and bring your innovative ideas to life.</p><p data-sourcepos="11:1-11:197"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable">&nbsp;<iframe width="100%" height="180" frameborder="no" scrolling="no" seamless="" src="https://share.transistor.fm/e/121f6d77" class="fr-draggable"><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><h2>About Circuit Break</h2><p data-sourcepos="1:1-1:333" id="isPasted">The Circuit Break podcast is hosted by Parker Dillmann and Stephen Kraig, two electrical engineers with a passion for technology. The podcast explores the latest innovations, industry news, and practical challenges in the field of electrical engineering. Some of the topics discussed on the podcast include: &nbsp;&nbsp;</p><ul data-sourcepos="3:1-7:0"><li data-sourcepos="3:1-3:126"><strong>DIY projects:</strong>Parker and Stephen often discuss their own DIY projects, sharing tips and tricks for success. &nbsp;&nbsp;<div data-test-id="sources-carousel-source"><br></div></li><li data-sourcepos="4:1-4:136"><strong>Industry news:</strong>The hosts keep listeners up-to-date on the latest trends and developments in the electronics industry. &nbsp;&nbsp;<div data-test-id="sources-carousel-source"><br></div></li><li data-sourcepos="5:1-5:201"><strong>Interviews with industry experts:</strong>Parker and Stephen have interviewed a number of experts in the field, providing listeners with insights into the latest technologies and challenges. &nbsp;&nbsp;<div data-test-id="sources-carousel-source"><br></div></li><li data-sourcepos="6:1-7:0"><strong>Practical challenges:</strong> The hosts discuss the challenges that engineers face in their day-to-day work, such as design for manufacturing (DFM) and assembly. &nbsp;&nbsp;</li></ul><p>MacroFab has over 400 Circuit Break podcast episodes available on demand. &nbsp;Need something new to listen to? &nbsp;<a href="https://www.macrofab.com/podcasts/" target="_blank" rel="noopener noreferrer">Try one now</a>.&nbsp;</p></div><p><br></p><p><br></p><p><button><div hidden=""><br></div></button><button><div hidden=""><br></div></button></p><p><br></p><p><br></p><p><br></p>

You have a high-mix, low-volume product, but what do you do if your manufacturing partner prefers higher volume jobs? 

What You Need to Know About HMLV--High Mix Low Volume Production

<p id="isPasted">Injection molding vs. 3D printing doesn’t have to be an either/or proposition. Some projects use both processes during a product’s lifecycle. Traditionally, 3D printing has been used for prototyping and injection molding has been used for production. Additive manufacturing has advanced, however, and 3D printed parts aren’t limited to prototypes anymore.</p><p>Today, there are 3D printing technologies that can create production-quality components – and in the volumes you may require. These technologies include <a href="https://bmf3d.com/" target="_blank" rel="noopener">Projection Micro Stereolithography (PµSL)</a> from Boston Micro Fabrication (BMF), a form of microscale 3D printing that supports the use of plastics, metal-plated plastics, ceramics, hydrogels, and composites resins.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730085049022-Metal-plated-turbine.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Metal-plated 3D printed plastic parts</span></span></span></p><section id="isPasted"><p>3D printing has many advantages, but there’s often a part volume – a crossover point – where injection molding is used. With plastic injection molding, tooling that costs tens or even hundreds of thousands of dollars can be amortized across these high production volumes. Quantity is just one consideration, however, so consider these ten factors when comparing injection molding vs. 3D printing for your project.</p><ol><li>Lead Times</li><li>Setup Costs</li><li>Volumes</li><li>Materials</li><li>Part Size</li><li>Part Tolerances</li><li>Part Strength</li><li>Design Maturity</li><li>Design Complexity</li><li>Surface Finish</li></ol><p>The following sections explain.</p></section><section><h3><strong>#1 Lead Times</strong></h3><p>The steel or aluminum molds that are used with injection molding can take weeks or months to machine. The injection molder then sends a customer part samples for functional testing and dimensional measurements. If the initial samples aren’t suitable, the mold maker may have to adjust the tool, which extends project timetables.</p><p>3D printing has shorter lead times. Unlike injection molding, there’s isn’t a metal tool that needs to be CNC or EDM machined. Customers still need part samples, but there isn’t a mold to modify if changes are required – and the settings on a 3D printer can be adjusted. Using 3D printing, it’s even possible to produce low-volume injection molds. &nbsp;For high volumes in a single run, however, injection molding is faster.</p></section><section><h3><strong>#2 Setup Costs</strong></h3><p>Most injection molding costs are associated with the tool. Steel costs more than aluminum, and both metals cost more than the 3D plastics that are used to build some low-volume molds. Production molds cost more than prototype molds as well. With injection molding, tooling costs also vary with mold size and complexity. 3D printing eliminates these costs and the variability that comes with them.</p></section><section><h3><strong>#3 Volumes</strong></h3><p>There are four volumes of parts to consider when comparing injection molding vs. 3D printing: initial order quantity, annual order quantity, total quantity, and crossover volume. Standard parts have a crossover volume in the low thousands. Small, high-precision parts have crossover volumes in the tens of thousands, and that’s part of the reason <a href="https://bmf3d.com/ultra-high-resolution-3d-printers/">BMF’s microscale 3D printers</a> are used instead of micro injection molding.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730085117712-1730085117712.png" class="fr-fic fr-dib"></p><section id="isPasted"><h3><strong>#4 Materials</strong></h3><p>Injection molding and 3D printing support many of the same materials. Examples include ABS, acetal, acrylic, PEEK, PEI, polycarbonate, polyethylene, and PTFE. The end-use properties of injection molded and 3D printed materials aren’t the same, however, and injection molding supports some materials that 3D printing does not, and vice versa. With BMF’s open material system, designers can print with the materials of their choice (including non-plastics) or with BMF’s own specially formulated polymers.</p></section><section><h3><strong>#5 Part Size</strong></h3><p>Micro injection molding can produce small parts, but with high tooling costs and practical limitations such as the size of the mold, the capabilities of the machine, and the part’s minimum wall thickness. Most 3D printers can’t produce microscale components, but PµSL technology can print parts that are <a href="https://www.zdnet.com/article/exclusive-zdnet-interview-bmf-ceo-john-kawola-on-3d-printing-parts-smaller-than-a-human-hair/">smaller than a human hair</a>, which is roughly 70 microns across. PµSL doesn’t just rival precision injection molding in terms of size, however. This form of 3D printing can also achieve extremely tight tolerances.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730085142908-MicroScrew4-scaled.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Micro Nut and Bolt with M0.3 Threads</span></span></span></p><section id="isPasted"><h3><strong>#6 Part Tolerances</strong></h3><p>For non-critical applications, the <a href="https://www.fictiv.com/articles/injection-molding-tolerances-7-questions-for-designers">tolerance of injection molded parts</a> is usually ± 0.1 mm. For critical components, such as those used in medical applications, ± 0.025 mm is typical. With PµSL technology, manufacturing tolerances are measured in terms of microns instead of millimeters (mm). Given that 1 micron equals 0.001 millimeter, PµSL printing tolerances of ± 10µm ~ ± 25µm are especially tight.</p></section><section><h3><strong>#7 Part Strength</strong></h3><p>Injection molded parts tend to be stronger than 3D printed components. Mainly, that’s because injection molded parts are made are made of a single layer of material. By contrast, 3D printing produces parts layer by layer. Material selection matters, however, and <a href="https://bmf3d.com/blog/injection-molding-vs-3d-printing-ten-considerations/P%C2%B5SL">BMF materials</a> such as RG resin are durable engineering materials that can be used to produce functional end-use parts.</p></section><section><h3><strong>#8 Design Maturity</strong></h3><p>Injection molding is ideal for manufacturing parts with mature designs in high volumes. Once manufacturing begins, however, design changes are impractical. 3D printing readily supports design changes from prototyping through production. In other words, it’s easier to identify and correct problems without scrapping tools or wasting materials, a key consideration for designs that are still maturing.</p></section><section><h3><strong>#9 Design Complexity</strong></h3><p>Compared to injection molding, 3D printing supports greater complexity. From holes in the middle of parts to intricate shapes or spoke-like features, there’s greater design freedom with this form of additive manufacturing. With injection molding, the tool limits part design. For example, parts with right angles may break during ejection and ribs are needed for support.</p><span contenteditable="false" class="fr-img-caption fr-fic fr-dib fr-draggable" style="width: 832px;" draggable="false"><span class="fr-img-wrap"><a href="https://bmf3d.com/wp-content/uploads/2020/06/chip-array-socket2.jpg" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730085185905-chip-array-socket2.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner" contenteditable="true">Chip Array Socket with Arrays of 130µm Through Holes</span></a></span></span></section><section id="isPasted"><h3><strong>#10 Surface Finish</strong></h3><p>Finally, comparisons of injection molding vs. 3D printing need to account for surface finish. Generally, 3D printed parts have a rougher surface finish; however, post-build smoothing can be used. Injection molded parts can have a fine finish, but with higher tooling costs. With plastic injection molding, parts are also subject to surface defects such as mold flash.</p></section><section><h2><strong>Comparing Injection Molding vs. 3D Printing</strong></h2><p>Injection molding is ideal for high-volume production and for projects with longer turnaround times. Although it can be used with parts of various sizes, injection molding offers less design freedom. 3D is better for low-volume production runs, designs with frequent changes, and projects with quick turnaround times.</p><p>There are many types of 3D printers, but PµSL technology from Boston Micro Fabrication (BMF) lets designers get prototypes and production-quality parts in small sizes – and without the high costs of micro injection molds.</p></section></section></section>

Injection molding vs. 3D printing doesn’t have to be an either/or proposition. Some projects use both processes during a product’s lifecycle. Traditionally, 3D printing has been used for prototyping and injection molding has been used for production.

Injection Molding vs. 3D Printing: Ten Considerations

<p id="isPasted">In wireless product development, what happens behind the scenes when selecting, designing, and integrating an antenna into a product? What is the journey of a PCB antenna, or more specifically, a PCB-mounted embedded antenna?</p><p>Designing and integrating an antenna may seem complex, but it can be broken down into manageable steps. It begins with defining the product’s requirements, which drive the antenna specifications. Next, you select and design the appropriate antenna type. Then, verify the design’s performance through simulations. After building and testing prototypes, manufacturing begins.</p><p>Each step demands careful attention. This article offers a clear, step-by-step guide to the PCB antenna design process, explaining each stage and providing practical tips to help you successfully integrate the antenna into your wireless product.</p><h2><p>Step 1: Requirements Engineering</p></h2><p>The first step in designing an antenna for wireless solutions is to identify and document the product's essential needs. This process is known as Requirements Engineering (RE).</p><p>RE focuses on understanding what needs to be designed, not how. To effectively define these requirements, the design team must conduct a thorough problem analysis. This analysis should address several critical questions to ascertain the operational and environmental conditions under which the product will function. These include:</p><ul><li>What types of communication protocols will the product support (e.g., WiFi, cellular, GPS)?</li><li>What operating frequency and bandwidth are required?</li><li>What are the coverage, gain, and cost expectations?</li><li>Will the product operate indoors, outdoors, or under specific environmental conditions such as extreme temperatures or high humidity?</li><li>How much space can be afforded for antenna clearance on the PCB?</li></ul><p>The product requirements define the necessary antenna specifications, which help narrow down the possible antenna technologies. When proposing antenna solutions, include a detailed assessment of the costs, timeline, and, if possible, recommendations for placement and orientation.</p><p>Document all antenna and product requirements in a way that supports testing. These requirements should guide the design process and serve as a checklist during testing to ensure the design meets the goals.</p><h2><p>Step 2: Design</p></h2><p>The design stage starts by using the requirements defined in the RE phase to select the appropriate antenna type and design its specifications to meet those needs.</p><p>The antenna must be designed to cover the required frequency and range. Its key parameters, such as efficiency and directionality, should align with the product’s needs. The polarization of both the transmitting and receiving antennas must match to maximize power transfer. The Voltage Standing Wave Ratio (VSWR) should be kept low and the return loss high.</p><p>When attaching the antenna to a PCB, match the antenna's impedance with the characteristic impedance of the feed line connecting it to either a transmitter or a receiver. Impedance mismatches can significantly reduce the RF link budget, lowering the antenna's efficiency and range.</p><p>Remember, an antenna is a sensitive component. Its performance is greatly influenced by its placement, surrounding components, the ground plane, and the enclosure or casing.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729781924459-1729781924459.png" alt="Antenna design pcb" class="fr-fic fr-dii"></p><ul><li><strong>Antenna Placement:</strong> Antenna placement on the PCB is crucial. Datasheets often suggest various placement options. Choose one of these for optimal performance. If you need to place the antenna elsewhere, you'll need to validate the placement through careful study.</li><li><strong>Nearby Components:</strong> Placing metallic objects near an antenna can interfere with its performance. Metallic objects reflect the antenna’s radiated energy back to the antenna. It’s best to avoid this, or at least account for these components when designing and tuning the antenna. Finalize the device's mechanical layout before tuning the antenna, as changes later on can disrupt the tuning.</li><li><strong>PCB Size and Ground Clearance:</strong> PCB size is crucial for ground-dependent antennas because the board itself affects radiation. Follow ground clearance guidelines in datasheets to avoid poor performance due to detuning or reduced efficiency.</li><li><strong>Casing:</strong> Materials used to manufacture the device casing can be critical for the antenna’s performance. This is even more critical for small antennas. If the dielectric material properties are available, it is better to choose a material with low permittivity and dielectric losses that are as low as possible. Such materials are virtually transparent to the antenna’s radiation.</li></ul><p>For more in-depth guidance during antenna design, refer to our previous white paper covering six essential considerations for PCB antenna design.</p><h2><p>Step 3: RF Simulation</p></h2><p>To shorten and ensure reliable design cycles for PCB antennas, designs must be verified early on. However, predicting antenna performance is challenging, as solving Maxwell's equations requires complex algorithms. Electromagnetic simulators can help predict performance and optimize antenna designs before building physical prototypes.</p><p>Remember, however, these simulators are tools, not replacements for the designer. They can predict performance based on the designs you give them, but you need a strong understanding of antenna theory to use them effectively.</p><p>Choosing the right simulation method is also important. Popular algorithms include the Method of Moments (MoM), Finite Element Method (FEM), Finite Difference Time Domain (FDTD), and Finite Integration Technique (FIT). Each has specific advantages and disadvantages summarized below:</p><table><thead><tr><th scope="col">Algorithm</th><th scope="col">Advantages</th><th scope="col">Limitations</th></tr></thead><tbody><tr><td>Method of Moments (MoM)</td><td><ul><li>Analyzes complex layered structures effectively.</li><li>Simulates designs with many ports efficiently, without added time costs.</li></ul></td><td><ul><li>Cannot handle general 3D structures, limiting its use to planar designs.</li><li>Demands large storage and increases computational time sharply with the size of the problem.</li></ul></td></tr><tr><td>Finite Element (FEM)</td><td><ul><li>Can analyze arbitrarily shaped 3D structures, not just layered setups, offering an advantage over the MoM.</li><li>Simulates designs with many ports efficiently, without added time costs.</li><li>Offers the most flexible approach to electromagnetic analysis.</li><li>Serves as a frequency-domain solver, making it ideal for problems with periodicity like phased arrays, frequency-selective structures, and band gap antennas.</li></ul></td><td><ul><li>Simulating complex antenna structures uses significant computer memory.</li></ul></td></tr><tr><td>Finite Difference Time Domain (FDTD)</td><td><ul><li>Can analyze 3D structures.</li><li>It has an advantage over the FEM method in that it does not require solving a matrix, allowing it to handle very large problems with relatively small amounts of computer memory.</li><li>Highly suitable for parallel processing, which allows it to leverage modern GPUs to speed up simulations.</li><li>Simpler to implement a basic FDTD solver compared to MoM and FEM solvers.</li><li>Well-suited for simulating specific antenna types such as horn antennas, waveguides, microstrip antennas, conformal antennas, and small planar array antennas.</li></ul></td><td><ul><li>Requires running a separate simulation for each port in a design, making it less efficient for designs with many ports.</li><li>Not optimal for certain types of antennas like wire antennas, aperture antennas, reflector antennas, and those with electrically large structures.</li></ul></td></tr><tr><td>Finite integration technique (FIT)</td><td><ul><li>Effective for analyzing antennas with inhomogeneous materials, wideband issues, and ultra-wideband (UWB) applications.</li><li>FIT underpins many commercial simulation tools because it can handle the entire spectrum of electromagnetics, from DC to high-frequency and optical applications.</li></ul></td><td><ul><li>Not well-suited for simulating wire antennas.</li></ul></td></tr></tbody></table><h3><p>Choosing the Right Simulation Method</p></h3><p>Selecting the appropriate EM(Electromagnetic) analysis tool depends on factors like ease of model creation, integration with circuit simulation tools, and the level of EM expertise required.</p><p>For planar structures, such as PCB interconnects and planar antennas, the MoM is most effective. For fully 3D structures like connectors, packages, and 3D antennas, FEM or FDTD methods are better.</p><p>For complex 3D structures with many ports, FEM is ideal. FDTD is best for large structures with fewer ports, such as antenna placements on vehicles or aircraft, and for evaluating antenna performance near detailed human body models.</p><h2><p>Step 4: Performance Tests and Optimization</p></h2><p>After optimizing the designs, prototypes are built for testing. These tests take place in an anechoic chamber designed to absorb all sound waves. Key measurements include return loss, efficiency, maximum gain, Effective Isotropic Radiated Power (EIRP), Total Radiated Power (TRP), Total Isotropic Sensitivity (TIS), and impedance. These measurements fully assess the antenna’s performance. If the results show any issues, the design can be adjusted.</p><p>Testing falls into two categories: passive and active.</p><p>Passive antenna testing evaluates the antenna alone, without the influence of the rest of the device. The antenna port is isolated from the RF front end and connected to a vector network analyzer (VNA) set to specific frequencies and amplitudes. The VNA measures data, which is then used to calculate efficiency, gain, directivity, and EIRP.</p><p>Active antenna testing measures the antenna as part of the entire system, including the RF front end. The main measurements are TRP and TIS.</p><p>TRP measures the total power radiated by the antenna when it is transmitting across a frequency band. TIS measures the average sensitivity of the receiving antenna system over a frequency band. TRP and TIS are key indicators of signal quality, offering a reliable gauge of the system’s overall performance.</p><h3><p>Practical Considerations During Testing</p></h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729781924565-1729781924565.png" alt="Antenna design considerations" class="fr-fic fr-dii"></p><ul><li>If possible, make the prototype from the same materials, using the same manufacturing processes and facilities as the final product. This ensures accurate testing.</li><li>Start critical measurements and prototype testing early. This speeds up the successful production of the final product.</li><li>Antennas must be customized to their specific environment and materials, as they may not perform as expected based on datasheets. Testing should simulate real-world conditions by considering the intended use cases and positions, such as near the head, body, or on different surfaces.</li><li>When planning tests, verify if the product must meet specific regulatory requirements. For instance, for cellular IoT devices, TRP and TIS are crucial, as failing to meet carrier standards for these parameters can prevent product approval.</li><li>Follow regulatory standards for electromagnetic emissions and safety. Include electromagnetic emissions compliance checks throughout the design and testing process. This ensures legal compliance and prevents interference with other devices.</li></ul><p>Antenna testing offers significant advantages. It allows designers to optimize the antenna’s design for better radio performance, considering factors like product size, typical use, manufacturing costs, and RF exposure. Even a small improvement, such as a 6 dB gain, can double coverage, while a 3 dB gain can cut the power amplifier’s energy consumption in half, leading to longer battery life. As a result, users experience extended range and enhanced signal quality.</p><h2><p>Step 5: Manufacturing</p></h2><p>The final step is manufacturing. Success in this stage depends on a stable design, a reliable production process, and effective end-of-line testing. Even the best designs are useless if they can't be produced efficiently and with high quality. To achieve this, consider the following when selecting and collaborating with a manufacturer:</p><ul><li><strong>Early Collaboration:</strong> Involve the manufacturer early in the design process. Close collaboration between design, manufacturing, and materials teams throughout all stages—from design and prototyping to production—ensures a smooth transition to manufacturing, saving time and costs.</li><li><strong>Quality Assurance:</strong> Choose a manufacturer that offers robust quality assurance, including innovative end-of-line testing methods. Ensure any overseas facilities comply with local legal standards and maintain strict confidentiality agreements.</li><li><strong>Timely Production:</strong> The manufacturer must meet your deadlines and pricing requirements without compromising on quality. Confirm their average lead time to ensure they will deliver on schedule and within budget.</li><li><strong>Fabrication Tolerances:</strong> Select a fabrication process capable of meeting tight tolerances. Use prototyping and testing to evaluate the manufacturer’s capabilities and limitations and how their fabrication tolerances impact antenna performance.</li></ul><h2><p>Conclusion</p></h2><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729781924596-1729781924595.png" alt="Red pcb design" class="fr-fic fr-dii"></p><p>Designing and manufacturing antennas is a complex process. It is crucial for the success of any wireless product. Choosing the right partner is essential. The design team must work closely together. They need to understand the product’s requirements. They must also follow regulations on frequency, power output, EMC, and testing.</p><p>The design should consider factors like PCB size, ground plane, casing, placement, and nearby components. Early design verification is important. Rapid prototyping helps speed up production. Ultimately, even the best designs are only valuable if they can be manufactured efficiently.</p><h4 id="isPasted">Ready to start your PCB Antenna prototype?</h4><p><a href="https://factory.macrofab.com/quick_quote?utm_term=electronic%20manufacturing%20systems&utm_campaign=ampliva-search-electronics-manufacturing&utm_source=bing&utm_medium=cpc" target="_blank">Get an Instant Quote Now</a></p><p><br></p>

Making your prototype from the same materials using the same manufacturing processes and facilities as your final product ensures accurate testing and better final results. This article also outlines other best practices. 

PCB Antenna Design: A Step-by-Step Guide

<p id="isPasted">In the fast-paced world of electronics and innovation, having access to the right tools is essential for designers and engineers looking to bring their concepts to life quickly and efficiently. Development kits are a key resource in this process, offering pre-built solutions that allow for faster prototyping and testing of new ideas. Mouser Electronics, a leading global distributor, is renowned for providing one of the most extensive ranges of off-the-shelf development kits, ensuring that designers can access the tools they need when they need them.</p><p>In this article, Mouser’s Director of Technical Content for EMEA, Mark Patrick, shares his expert insights by presenting his ‘Top 5 Picks’ from the latest development kits available. These kits have been carefully selected based on their innovative features, ease of use, and the potential they offer to accelerate the design process. Whether you're working on AI applications, IoT solutions, or embedded systems, these development kits can give your project the jumpstart it needs.</p><h2><strong>Long-range connectivity</strong></h2><p><em>Digi XBee® XR 868&nbsp;</em></p><p>This development kit includes the Digi XBee 868 RF MHz module with a U.FL antenna connector, antennas, and a development board. It supports long-range connectivity applications in Europe, operating between 863MHz and 870MHz. The module facilitates point-to-point and mesh networking with a line-of-sight range exceeding 14 kilometers, ideal for the agriculture and energy sectors. The device employs intelligent interference management using Listen Before Talk and Adaptive Frequency Agility, reducing interference by scanning frequencies and shifting channels seamlessly.</p><p><a href="https://www.mouser.com/new/embedded-solutions/engineering-tools/digi-xbee-xr-868-kit/n-8mwysZ1npagf">XBee® XR 868 Development Kit - Digi | Mouser</a></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729582453944-digi.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2><strong>Curiouser and curiouser</strong></h2><p><em>Microchip WBZ450 EV22L65A</em></p><p>Microchip’s WBZ450 Curiosity board is an efficient, modular development platform that supports rapid prototyping and demonstrates the features, capabilities, and interfaces of Microchip’s WBZ450PE BLUETOOTH® Low Energy and Zigbee® RF module. The EV22L65A board offers integrated programming/debugging features using the PICkit™ Onboard 4 (PKOB4) debugger interface. A Micro-USB cable is required to power up and program the board.</p><p><a href="https://www.mouser.com/new/embedded-solutions/engineering-tools/microchip-ev22l65a-board/n-8mwysZ2puw22">WBZ450 Curiosity Board (EV22L65A) - Microchip Technology | Mouser</a></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729582723571-micro.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2><strong>Arm-based MCU&nbsp;</strong></h2><p><em>STMicro STM32H7S78-DK Discovery kit</em></p><p>STMicroelectronics’ STM32H7S78-DK Discovery kit demonstrates and develops applications for the Arm® Cortex®-M7 core-based STM32H7S7L8H6H microcontroller. The kit comes with various hardware features, including USB Type-C™, Octo-SPI flash memory, Hexadeca-SPI PSRAM devices, audio codec, digital microphones, ADC, user button, and flexible extension connectors. These connectors facilitate easy wireless connectivity, analog applications, and sensor expansion.</p><p><a href="https://www.mouser.com/new/embedded-solutions/engineering-tools/stm-stm32h7s78-dk-kit/n-8mwysZ2cjsva">STM32H7S78-DK Discovery Kit - STMicro | Mouser</a></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729582777405-st.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h2><strong>Rugged and reliable embedded wireless</strong></h2><p><em>Advantech WLNNA&nbsp;</em></p><p>Advantech’s WLNNA Series evaluation kit is a platform for evaluating, testing and developing Airborne Enterprise Device Server Modules. The Advantech WLNNA kit offers size, cost, power consumption, and performance advantages over other wireless solutions. Ideal for rugged and reliable applications needing an embedded IEEE 802.11a/b/g/n compliant wireless engine, the kit includes a WLNNA Series Evaluation Board with connectors and headers providing access to all module interfaces.</p><p><a href="https://www.mouser.com/new/embedded-solutions/engineering-tools/advantech-wlnna-kit/n-8mwysZ27k4mu">WLNNA Series Evaluation Kit - Advantech | Mouser</a></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729582820389-brief+2.png" style="width: 100%px;" class="fr-fic fr-dib"></p><h2><strong>IoT control</strong></h2><p><em>M5Stack M5NanoC6 board</em></p><p>This board features an ESP32-C6FH4 MCU supporting Wi-Fi 6, Zigbee®, and an infrared emitter for controlling infrared IoT devices. The device's ceramic antenna ensures stable wireless communication. Programmable RGB beads enable personalized visual effects. The Grove interface allows flexible expansion of various M5 devices, which are customizable for different communication protocols.</p><p><a href="https://www.mouser.com/new/embedded-solutions/engineering-tools/m5stack-m5nanoc6-board/n-8mwysZ2sl8dv" id="isPasted">M5NanoC6 Board - M5Stack | Mouser</a></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729582849615-m5.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p>

In this article,  Mouser’s Director, Technical Content, EMEA, Mark Patrick, presents his ‘Top 5 Pick’ of recently-released dev kits.

The development tools you need

<section id="isPasted"><p>The global push for renewable energy is undeniable. Fueled by a potent combination of international cooperation and escalating climate concerns, renewable energy is experiencing a surge. At the United Nations Framework Convention on Climate Change (COP28) in December 2023, over 130 countries committed to tripling renewable energy capacity to 11,000 GW by 2030. Underscoring this commitment, GWEC Market Intelligence projects a significant expansion of 791 GW of new wind energy capacity in the next five years under current policies. With a <a href="https://www.mckinsey.com/industries/electric-power-and-natural-gas/our-insights/offshore-wind-strategies-for-uncertain-times" target="_blank">vast theoretical potential of up to 70,000 GW</a> according to recent data shared by McKinsey, offshore wind is poised for significant growth.</p><p>However, maintaining these colossal turbines, often located miles out at sea, presents a unique set of challenges. Traditional manual inspection methods relying on industrial climbers are risky, time-consuming, and expensive. This is where drone technology steps in, offering a game-changing solution for offshore wind turbine inspections.</p><h2><p>Safety First: Reducing Worker Risk</p></h2><p>Inspecting offshore wind turbines exposes workers to many dangers. From falls from heights and electrical shock to the perils of working in confined spaces, the risks are considerable. With ever-increasing turbine heights, like GE's Haliade-X reaching a staggering 850 feet, these hazards become even more pronounced.</p><p>Drone solutions can solve these challenges in a transformative way. By eliminating the need for human climbers, drones significantly enhance safety and reduce the risk of accidents. Additionally, drones can conduct inspections more frequently, enabling the early detection of potential issues and preventing costly downtime through more regular inspections.</p><h2><p>Enhanced Efficiency: Faster, More Cost-effective Inspections</p></h2><p>Time is money, especially in the offshore wind industry. Traditional inspections take hours, impacting turbine operations and productivity. Drones significantly reduce inspection time. Studies suggest a potential 80% reduction in inspection time compared to manual methods, leading to substantial cost savings.</p><p>Furthermore, drones offer a more comprehensive inspection approach. They can reach previously inaccessible areas and provide detailed, high-resolution images for thorough analysis. This allows for the identification of even minor defects before they become major problems, preventing costly downtime and repairs.</p><h2><p>Technological Advancements: A Look at the Cutting Edge</p></h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729194076738-1729194076738.png" alt="1turbine8923475 copy" class="fr-fic fr-dii"><p>Drone technology constantly evolves, offering advanced solutions for wind turbine inspections. Here are some key areas of progress:</p><ul><li><strong>Mobile Thermography:</strong> These drones use thermal imaging sensors to detect variations in heat flow across turbine blades. Areas with structural defects will show up as cooler spots, allowing for early detection of damage before it becomes critical.</li><li><strong>Lidar Inspections:</strong> Lidar (Light Detection and Ranging) technology provides visual inspections using high-resolution, 3D images of the turbine blades. While these inspections require slower, closer flybys, advancements in battery technology increases flight time, allowing drones to complete inspections of all blades without a recharge.</li></ul><p>However, the offshore wind industry has recently faced challenges. Stakeholders have expressed concerns over a high rate of project cancellations following significant cost increases. Despite these setbacks, the long-term potential of offshore wind remains substantial, and the industry is actively seeking innovative solutions to overcome these hurdles.</p><p>Drones play a crucial role in addressing these challenges by optimizing operations and reducing costs. By collecting vast amounts of data, drones enable predictive maintenance strategies, allowing operators to schedule maintenance proactively, allocate resources efficiently, and extend turbine lifespan.</p><p><strong>Learn more about <a href="https://www.macrofab.com/blog/drone-pcba-tackling-sensor-integration/" target="_blank">sensor integration in drones</a> now.</strong></p><h2><p>Data-Driven Decisions: Empowering Predictive Maintenance</p></h2><p>Drones collect a wealth of valuable data during inspections. High-resolution images, thermal readings, and 3D point cloud data from Lidar scans can be analyzed using sophisticated software. This data allows for the creation of digital twins – virtual replicas of the turbines – that can be used to predict potential problems before they occur.</p><p>Predictive maintenance, enabled by drone data, empowers wind farm operators to:</p><ul><li><p><strong>Schedule maintenance proactively:</strong> Instead of waiting for a turbine to fail, inspections can be targeted based on the collected data, optimizing maintenance schedules and reducing downtime.</p></li><li><p><strong>Optimize resource allocation:</strong> By identifying specific areas of concern, resources can be directed efficiently, reducing overall maintenance costs.</p></li><li><p><strong>Extend turbine lifespan:</strong> Early detection and repair of minor issues can prevent them from escalating into major problems, ultimately extending the turbine’s lifespan.</p></li></ul><h2><p>A Collaborative Approach: Humans and Drones Working Together</p></h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729194076496-1729194076496.png" alt="2turbine498yhud copy" class="fr-fic fr-dii"><p>While drones offer significant advantages, they cannot replace human expertise completely. A successful drone inspection program thrives on a collaborative approach:</p><ul><li><p><strong>Skilled Drone Pilots:</strong> Experienced pilots are essential for safe and efficient operation in challenging offshore environments. Their expertise in navigating wind conditions and maneuvering around turbines ensures the integrity of the data collected.</p></li><li><p><strong>Data Analysts:</strong> The vast amount of data collected by drones requires skilled data analysts. These professionals interpret the data, identify trends, and generate actionable insights for wind farm operators.</p></li><li><p><strong>Maintenance Crews:</strong> Once potential issues arise, human technicians remain vital for repairs and maintenance activities. Drones provide the initial assessment, but human expertise is crucial for addressing the identified problems.</p></li></ul><p>This collaborative approach leverages the strengths of both humans and machines. Drones handle the high-risk and repetitive aspects of inspections, while human expertise focuses on analysis, decision-making, and the complex tasks requiring manual intervention.</p><h2><p>Challenges and Considerations</p></h2><p>While drone technology offers immense benefits, there are still challenges to overcome. High winds significantly impact drone maneuverability and control, requiring experienced operators familiar with the specific challenges of flying around wind turbines. Salt spray from the ocean also affects drone components, making regular maintenance crucial.</p><p>Successful drone inspection programs emphasize careful planning and preparation. Autonomous flight capabilities minimize operator error and allow for precise control, especially in challenging weather conditions.</p><h2><p>The Role of PCBAs in Drone Technology</p></h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729194076109-1729194076109.png" alt="3turbine98tuo copy" class="fr-fic fr-dii"><p>The widespread adoption of drones for offshore wind turbine inspections underscores the critical role of <a href="https://www.macrofab.com/pcba/" target="_blank">Printed Circuit Board Assemblies (PCBAs)</a> in this rapidly growing industry. PCBAs serve as the "brain" of drones, integrating essential components like sensors, processors, and communication systems. These intricate boards enable drones to navigate complex environments, capture high-resolution images, and transmit data efficiently.</p><p>As drone technology advances, the demand for more sophisticated PCBAs increases. Features such as enhanced processing power, miniaturization, and improved durability are essential for meeting the rigorous demands of offshore wind turbine inspections. Reliable and high-performance PCBAs are crucial for ensuring safe and efficient drone operation, ultimately contributing to the success of the offshore wind industry.</p><h2><p>The Future of Offshore Wind: A Symbiosis of Man and Machine</p></h2><p>The synergy between drones and advanced PCBAs is driving innovation in offshore wind turbine inspections. As the industry continues to expand, the development of cutting-edge PCBAs will be instrumental in maximizing the potential of drone technology and accelerating the transition to a clean energy future.</p></section><h4>Need high-quality PCBAs for your next drone build?</h4><p><a href="https://factory.macrofab.com/quick_quote/?utm_source=direct&utm_medium=none" target="_blank">Get an instant quote now</a></p><section><h5><br></h5></section>

Learn how reliable and high-performance PCBAs are crucial for ensuring safe and efficient drone operation, ultimately contributing to the success of the offshore wind industry.

How Drones are Transforming Offshore Wind Turbine Inspections

<h2 id="isPasted"><strong>Introduction</strong></h2><p>Polyether Ether Ketone (<strong>PEEK</strong>) is a high-performance engineering thermoplastic renowned for its outstanding mechanical properties, chemical resistance, and thermal stability. It finds utility in stringent sectors such as aerospace, medical, and electronics due to its robustness. While injection molding stands out as the most effective manufacturing method for crafting precise PEEK components, mastering this technique requires a deep understanding of both the material and the process, especially when using compact injection molding systems.</p><p><br></p><h3><strong>1. Material Properties of PEEK</strong></h3><p>PEEK is favored for high-performance applications owing to its distinctive characteristics:</p><p><strong>High Temperature Resistance:</strong> PEEK endures continuous exposure to temperatures as high as 250°C, making it suitable for components that experience high thermal loads.</p><p><strong>Chemical Resistance:</strong> Its resistance to a wide array of chemicals ensures durability in aggressive environments.</p><p><strong>Mechanical Strength and Toughness:&nbsp;</strong>PEEK offers superior strength and stiffness along with excellent wear resistance, which is crucial for parts subjected to high mechanical loads.</p><p><strong>Biocompatibility:</strong> Its compatibility with bodily tissues makes it ideal for medical implant applications.</p><h3>2. Challenges in Injection Molding PEEK</h3><p>Any injection molding machine, designed for precision and small-scale production, must be carefully calibrated for PEEK due to its high melting point (343°C) and unique processing requirements:</p><p><strong>Processing Temperatures:</strong> Optimal mold temperatures range between 160°C and 200°C, which helps achieve desired crystallinity. The injection temperatures should be maintained between 370°C and 400°C to facilitate smooth flow.</p><p><strong>Cycle Time:</strong> PEEK's inherent properties necessitate longer cooling times compared to more conventional thermoplastics, potentially impacting production efficiency.</p><p><strong>Mold Design:</strong> Given PEEK's minimal shrinkage, the mold must be designed with high precision to ensure accurate dimensional outcomes.</p><h3>3. Critical Mold Design Considerations</h3><p>Effective mold design is vital:</p><p><strong>Gate Design:</strong> Small, uniformly-sized gates such as pin or edge gates are recommended to minimize residual stresses.</p><p><strong>Ventilation:</strong> Proper venting is crucial to prevent gas entrapment and eliminate burn marks.</p><p><strong>Mold Surface Finish:</strong> A highly polished mold surface enhances flow, reducing friction and improving the quality of the finished parts.</p><h3>4. Injection Molding Parameters</h3><p>Tailoring the injection machine settings is crucial for optimal results:</p><p><strong>Injection Pressure:</strong> High pressures are necessary to adequately fill the mold.</p><p><strong>Injection Speed:</strong> A slow to moderate injection speed helps prevent shear heating and material degradation.</p><p><strong>Cooling and Crystallization:</strong> Effective cooling management is essential to control crystallization and prevent warping or deformation.</p><h3>5. Post-Molding Processes</h3><p>To further enhance the properties of PEEK parts, certain post-processing treatments may be required:</p><p><strong>Annealing:</strong> This heat treatment relieves internal stresses and enhances dimensional stability.</p><p><strong>Surface Treatments:</strong> Techniques such as polishing or coating can significantly improve the surface quality of the components.</p><h3>6. Common Defects and Troubleshooting</h3><p>Understanding common defects can aid in troubleshooting:</p><p><strong>Warping and Shrinkage:</strong> Maintain proper cooling rates and ensure uniform mold temperature control.</p><p><strong>Bubbles and Voids:</strong> Fine-tune injection pressure and verify material drying processes prior to molding.</p><p><strong>Burn Marks:</strong> Ensure sufficient venting and consider reducing the injection speed if necessary.</p><h3>Conclusion</h3><p>Mastering PEEK injection molding demands precise control over material properties, mold design, and processing parameters. By meticulously attending to these critical aspects, manufacturers can consistently produce high-quality, reliable PEEK components for advanced applications.</p><p>#peekparts #injectionmolding #apsxllc #peek #medicalparts #biomedical</p>

While injection molding stands out as the most effective manufacturing method for crafting precise PEEK components, mastering this technique requires a deep understanding of both the material and the process, especially when using compact injection molding machines.

Critical Aspects of PEEK Injection Molding Process

<p id="isPasted">The stage is set and the pressure is high in this final episode of <em>Circuit Showdown.</em></p><p>&nbsp;Michael, Renee, and Charles return to face their toughest challenge yet. After two intense rounds of competition and a bit of a curveball, they have one last design standing between them and the title of the first-ever <em>Circuit Showdown</em>. Who will be the champion?</p><p>&nbsp;Just when everything was going smoothly, Chief Mentor, Raymond Yin, let the contestants know that they’d need to create an IoT dashboard using the Arduino IoT Cloud to show their data visually.</p><p>&nbsp;An unexpected twist means that each contestant must quickly adapt. Now, they not only have to complete their designs in a short time frame, but also connect them to the cloud—bringing real-time data into the mix.</p><p>&nbsp;For these rising engineers, winning isn’t just about the prize; it’s about proving their ability to innovate under pressure.</p><p>&nbsp;“Winning this contest would be an awesome part of my career,” Michael shared. Renee chimed in, “I just really want to make the people who have helped me get to this point in my life so far, proud.”</p><p>&nbsp;With the clock ticking down, every second counts even more!</p><p>&nbsp;As they work to incorporate the Arduino IoT Cloud into their projects, the judges weigh in on the difficulty of this final step. They admit that it’s not impossible but will add another layer of difficulty, especially with time running out.</p><p>&nbsp;By the time the countdown reaches its final moments, the contestants step back from their workstations, exhausted yet hopeful.</p><h2>Final Presentations: A Battle of Ingenuity</h2><p>Each contestant presents their final design to the judges, walking them through their creative process and how they overcame the hurdles along the way. Every project is unique, blending practicality with innovation, but the challenge of incorporating IoT adds a new level of complexity.</p><p>&nbsp;For some, the cloud integration didn’t go exactly as planned and set them back.</p><h2>A Tough Decision</h2><p>The judges take time to discuss what they’ve seen. They know that choosing a winner won’t be easy. Each project brought something different to the table—whether it was creativity or technical skill.</p><p>&nbsp;While the projects were impressive and tied into their personal experience, the IoT twist separated those who could quickly adapt under the pressure.</p><p>&nbsp;As the deliberation continues, it becomes clear that this will be a close decision. The judges need to rely heavily on the criteria—functionality, usage of available resources, adherence to the theme, and originality. They will also need to consider how the contestants handled the unexpected twist.</p><h2>Who Will Win?</h2><p>With the decision made, the contestants are called back to hear the judges’ final thoughts. “All of you demonstrated incredible resilience and creativity,” the judges announce. “But only one of you can be crowned the champion of <em>Circuit Showdown</em>.”</p><p>&nbsp;As the final moments unfold, one contestant emerges as the champion, but the true victory belongs to all three—who walk away with confidence in their abilities and the experience of competing at the highest level.</p><p>&nbsp;Find out who will be the first-ever <em>Circuit Showdown</em> champion. Watch the <a href="https://www.mouser.com/circuit-showdown/?utm_source=wevolver&utm_medium=circuitshowdown&utm_campaign=episode4">finale episode</a> now.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/qkuIrHsNVPA?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span><br></p>

In the final episode of Circuit Showdown, three contestants face their toughest challenge yet: integrating an IoT dashboard into their designs. With time running out, the judges are left with a tough decision. Who will rise to the occasion and win the championship?

The Finale: Who Will Be Crowned Circuit Showdown Champion?

<p dir="ltr" id="isPasted">Cutting costs during research and development (R&amp;D) is a vital goal for companies looking to maintain a competitive edge. Elon Musk’s five-step cost-reduction method, as discussed in his biography, offers a practical framework for achieving this. In this article, we will explore the steps—questioning, eliminating, simplifying, and more—that can significantly lower R&amp;D costs.</p><h2 dir="ltr">&nbsp;<span class="fr-img-caption fr-fic fr-dii" style="width: 822px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729157147715-1729157147715.png" width="602" height="116" class="fr-fic fr-dii"><span class="fr-inner"><p dir="ltr" id="isPasted"><em>Musk’s Five-Step Cost-Reduction Method</em></p></span></span></span>1. Question: Do You Really Need This?</h2><p dir="ltr">Questioning is the cornerstone of Musk’s five-step cost-reduction method, but it is also the hardest step to implement. He encourages developers to question every part of their design, challenging established norms and assumptions. As Musk famously said, “Only through relentless questioning can you truly solve problems.”</p><p dir="ltr">Here are some examples of the kinds of questions you might ask:</p><ul><li dir="ltr"><p dir="ltr">Why is the part’s wall thickness 4mm? You need to question it.</p></li><li dir="ltr"><p dir="ltr">Why is the part made from carbon fiber? You need to question it.</p></li><li dir="ltr"><p dir="ltr">Why is the part manufactured using machining? You need to question it.</p></li><li dir="ltr"><p dir="ltr">Why does this part exist in the first place? You need to question it.</p></li></ul><p dir="ltr">By questioning everything, you can identify unnecessary complexity and opportunities for cost savings. For example, when designing the Starship rocket, Musk questioned the widely accepted use of carbon fiber for the rocket’s shell. After some calculations, he discovered that using carbon fiber would cost millions of dollars, while a stainless-steel alternative could be achieved for just a fraction of the cost. This level of questioning is what allows for real breakthroughs in cost reduction, while maintains the functionality.</p><h2 dir="ltr">2. Delete: Cut What Doesn’t Add Value</h2><p dir="ltr">After you’ve questioned every part of your product, the next step is elimination—removing anything that doesn’t directly contribute to the product’s functionality or value. As Musk advises, “Delete any part or process you can. You may have to add some back later, but if you don't end up adding back at least 10%, then you didn’t delete enough.”</p><p dir="ltr">This process of deleting could mean removing unnecessary components, features, or processes. For instance, in the example shown in Figure-1, optimized design was simplified by eliminating one part entirely. In the original design, two components (A and B) were welded together to perform a clipping function. Part B, which was machined, was removed, and its function was integrated into Part A, a sheet metal piece. By reducing the part quantities from two to one, not only was the need for welding eliminated, but the overall cost was also significantly lowered.</p><p dir="ltr">This method can yield substantial cost savings by eliminating unnecessary complexity right from the design phase.</p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dii" style="width: 822px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729157149415-1729157149415.png" width="361" height="227" class="fr-fic fr-dii"><span class="fr-inner">Figure-1. Consider the Possibilities of Removing Every Part a) Original Design b) Optimized Design</span></span></span></p><h2 dir="ltr">3. Simplify: The Power of Streamlining</h2><p dir="ltr">Once unnecessary parts have been removed, the next step is to simplify or optimize. This means refining the design and processes to make them as efficient as possible. A streamlined design not only reduces costs by using fewer components, but it also speeds up manufacturing, minimizes the risk of errors, and shortens assembly times.</p><p dir="ltr">In Musk’s five-step method, simplifying follows elimination, ensuring that the remaining components and processes are working in the most effective way. This could involve simplifying the manufacturing steps, selecting more efficient materials, or reducing complexity in the assembly process. Ultimately, optimization drives both cost savings and greater production efficiency.</p><p dir="ltr">For more instances of simplifying and optimizing part design, you might be inspired by this article:<a href="https://www.rpworld.com/en/resources/blog/simplifying-medical-device-design.html">&nbsp;Simplifying Medical Device Design</a>.</p><h2 dir="ltr">4. Accelerate: Use On-Demand Manufacturing</h2><p dir="ltr">The fourth step is to accelerate the cycle time. By speeding up processes, companies can reduce development timelines and bring products to market faster, which ultimately lowers costs.</p><p dir="ltr">One effective way to accelerate production is through on-demand manufacturing, which has transformed traditional manufacturing by allowing companies to produce only what they need, exactly when they need it. Particularly beneficial during the R&amp;D phase, where frequent design changes and iterative prototypes are common, on-demand manufacturing enables low-volume production, helping companies avoid the financial burden of overproduction or excess inventory. It also provides the flexibility to quickly adjust designs without incurring the high costs of retooling or scrapping large production runs, thus minimizing waste and accelerating time-to-market.</p><h2 dir="ltr"><strong>5. Automate: Boost Efficiency and Reduce Errors</strong></h2><p dir="ltr">The final step in Musk’s method is automation. Automating processes reduces human error, increases efficiency, and shortens lead times. This could involve incorporating robotics in assembly lines or using software to streamline workflows.</p><h2 dir="ltr">How RPWORLD’s On-Demand Manufacturing Supports Cost Reduction?</h2><p dir="ltr">While Musk’s five-step method—questioning, deleting, simplifying, accelerating, and automating—provides a powerful framework for cutting costs, RPWORLD specifically helps innovative companies bring products to market faster and more cost-effective while maintaining high quality. Here’s how our services contribute to cost savings:</p><ul><li dir="ltr"><strong>Low-volume Production</strong>: RPWORLD is specialized in rapid prototyping and on-demand manufacturing services, the low-volume production offers fast turnaround time and flexibility without sacrificing quality, perfect for R&amp;D or market testing.</li><li dir="ltr"><p dir="ltr"><strong>Comprehensive One-Stop Service</strong>:&nbsp;RPWORLD manufacturing services cover everything from CNC machining, injection molding, and sheet metal fabrication to a wide variety of finishing options such as painting, anodizing, printing, plating and basic assembly, ensuring that every part of your project is handled efficiently under one roof.</p></li><li><strong>Advanced Quality Control</strong>: RPWORLD uses state-of-the-art inspection equipment, including CMM, 3D scanners, flash measuring machine, optical spectrum analyzers and more, to ensure every component meets your exact specifications. Our multi-stage quality control process guarantees consistency and reliability at every step.</li></ul>

In this article, we will explore the steps—questioning, eliminating, simplifying, and more—that can significantly lower R&D costs.

5 Strategies to Simplify R&D and Reduce Costs

As sustainability requirements, government policies, and consumer demand continue to put pressure on the automotive market, the Dutch automotive industry is finding effective ways of integrating cutting-edge materials and sustainable design practices to redefine the future of mobility.


Design and Materials in the Dutch Automotive Industry: Innovations and Future Directions

<p dir="ltr" id="isPasted">We are pleased to introduce the latest edition of the <a href="https://www.raivereniging.nl/en/sections/rai-automotive-industry-nl/" target="_blank" rel="nofollow">RAI Automotive Industry NL</a> report, which provides an in-depth exploration of the Dutch automotive sector's transformative trajectory. This sector, situated at the nexus of rapid technological advancements and pressing global challenges, exemplifies a model of innovation, sustainability, and resilience in a highly competitive international landscape.</p><p dir="ltr">This issue covers core themes: smart and green mobility, sustainable manufacturing, human capital development, design and materials, and internationalization. Each of these pillars underscores the industry's commitment to integrating advanced technologies into mobility solutions, driving the future of transportation with a focus on efficiency, safety, and sustainability.</p><p dir="ltr">Below you can read an excerpt of one of the featured articles. Or download the full report for free here.&nbsp;</p><p dir="ltr"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI4NTY3NzA4OTgzLXJhaSBlbWFpbC5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-242823280704453" title="2024 RAI Dutch Automotive Industry Magazine" allowtransparency="true" src="https://form.jotform.com/242823280704453" frameborder="0" style="min-width:100%;max-width:100%;height:590px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span> </iframe>&nbsp;</span></p><p dir="ltr" id="isPasted">With strong investment from the industry, the government, and education in lifelong human development, The Netherlands is capable of demonstrating world-class quality and quantity of skilled professionals needed to tackle global challenges in the automotive industry. At the heart of this success is RAI Automotive Industry NL, a pivotal organization championing the development and continuous education of automotive professionals.</p><h2 dir="ltr">Building a Comprehensive Education Pipeline</h2><p dir="ltr">In The Netherlands, the pathway to a career in automotive engineering is uniquely comprehensive. In a discussion with Jean Pierre Heijster, the section manager at RAI Association responsible for Smart and Sustainable Manufacturing and Human Capital, he explains that the RAI Association has established an educational continuum that spans from vocational training to Bachelor’s, Master’s, and PhD programs in automotive engineering. &nbsp;</p><p dir="ltr">This structured approach ensures that individuals can progressively build their expertise and qualifications, adapting to the industry’s evolving demands. Heijster highlights the significance of the Center for Innovative Craftsmanship (MBO Automotive Center), which provides vocational-level training. Additionally, there is a strong attachment to the Automotive Center for Expertise (ACE Mobility), a public-private partnership between education and industry.</p><p dir="ltr">One of the standout programs in which RAI Automotive Industry NL is involved is the Green SKHy project, a European initiative focused on developing training for professionals working with hydrogen systems in the automotive industry. This project underscores the importance of preparing the workforce for future technologies, ensuring that the Dutch automotive sector remains at the forefront of sustainable innovation. “We are part of this because we are certain we have to continuously train young people and make them aware of the fact that the automotive industry is the best industry to work in,” says Heijster.</p><p dir="ltr">This educational continuum is particularly vital in an industry marked by rapid technological changes. The automotive sector is experiencing a significant transformation, driven by advances in electric vehicles, hydrogen mobility, autonomous driving technologies, and sustainable energy sources. Adapting to these changes hinges on a well-educated workforce that is not only technically proficient but also agile and innovative. RAI Automotive Industry NL’s efforts in building a comprehensive education pipeline ensure that Dutch automotive professionals are equipped with the latest knowledge and skills, positioning them to lead the industry into the future.</p><h2 dir="ltr">Addressing the Skills Gap Through the Triple Helix Model&nbsp;</h2><p dir="ltr">The Dutch automotive industry’s success in human capital development is significantly attributed to the Triple Helix model, which promotes collaboration between government, academia, and industry. Heijster emphasizes that this model is the foundation of their human capital strategy. “The triple helix way of working is the base of the success of having a good human capital system. We’re still working on it day by day, but we can’t do it without the industry or the government,” he notes.</p><p dir="ltr">The Triple Helix model manifests in various collaborative initiatives, such as the Automotive Learning Community (TALCOM) project, where automotive companies, educational institutions, and government bodies create a hybrid learning environment. This environment allows students, teachers, researchers, and industry professionals to innovate and learn together, fostering a culture of continuous development and innovation. RAI Automotive Industry NL’s collaboration with the MBO Automotive Center and ACE Mobility, leading players in the Dutch automotive education sector, exemplifies this model’s effectiveness. Through joint efforts, they ensure the workforce is well-equipped with the necessary skills and knowledge to meet the industry’s current and future demands.</p><p dir="ltr">As a key member of RAI Automotive Industry NL, ACE Mobility connects education and industry by organizing activities and facilitating innovative research projects in collaboration with Fontys and HAN Universities of Applied Sciences, along with various leading partners from the automotive and mobility industry. “In addition to our focus on activities and research innovation projects, Human Capital has become a key pillar of our strategy,” says Saskia Lavoo, General Manager at ACE Mobility.</p><p dir="ltr">“By playing a crucial role in the Human Capital agenda in various national growth initiatives, for example, we help the sector address immediate and long-term challenges, equipping professionals and students with essential skills for future innovations,” Lavoo adds. “We try to achieve this with over 200 cooperating organizations, overseeing over 40 million in Human Capital activities in the upcoming 8 years.” Guided by principles of Safety, Sustainability, and Clean and Smart Mobility, ACE Mobility ensures the Dutch automotive industry remains competitive and innovative, contributing to a sustainable future.</p><p dir="ltr">Lavoo is optimistic about the future of the Dutch automotive industry, especially regarding human capital. “In the next ten years, I expect significant growth driven by increased demand for high-tech skills in automation and green technologies. But realistically, we foresee more problems in the next 20 years than what we together as an ecosystem can find a solution for.”</p><p dir="ltr">“Our focus will be on developing the competencies, ensuring that the Dutch sector is prepared and leading these changes. Our nationally led approach will reach various regions in order to make a difference directly with education and business through transition hubs, for example. We are setting up our first hub on Batteries at the Automotive Campus, as we speak,” she explains. Continuous learning and adaptation will be key to maintaining The Netherlands’ competitive edge globally.</p><p dir="ltr">ACE Mobility’s initiatives in Human Capital development and its role as an industry trendsetter are crucial. The Dutch automotive sector is set for growth, propelled by technological advancements and a skilled workforce, ensuring a sustainable and innovative future.</p><p dir="ltr">In a global context, the Dutch approach stands out for systematically integrating these three pillars. Many countries struggle with fragmented efforts where education, industry, and government tend to operate in silos. The Triple Helix model breaks down these barriers, creating a cohesive ecosystem that drives both educational and industrial advancements. This integrated approach not only addresses the immediate skills gap but also fosters long-term collaboration and innovation, ensuring that the Dutch automotive industry can respond swiftly to emerging trends and technological disruptions.</p><h2 dir="ltr">Lifelong Learning: A Necessity in the Fast-Paced Automotive Sector&nbsp;</h2><p dir="ltr">Technological advancements in the automotive industry are rapid and relentless. To keep pace, professionals must engage in lifelong learning, continuously updating their skills and knowledge. The RAI Association plays a crucial role in facilitating this ongoing education. “Those who are already working in the automotive industry also have continuous learning programs because technology is growing so fast. Either you continuously learn and develop yourself, or you will lose,” asserts Heijster.</p><p dir="ltr">These continuous learning programs are developed in collaboration with universities, universities of applied sciences, and vocational education institutes. They cater to the needs of both new entrants and seasoned professionals, ensuring that everyone in the industry can stay abreast of technological advancements and industry trends.</p><p dir="ltr">A key component of these programs is their focus on practical, hands-on learning experiences. For instance, TALCOM at the Automotive Campus in Helmond brings together companies like DAF Trucks and Ebusco with educational institutions such as Fontys and Summa. This collaboration enables students and professionals to work on real-world projects, applying their theoretical knowledge to real-world challenges. By engaging in these experiential learning opportunities, participants gain a deeper understanding of the industry’s intricacies and develop the skills needed to drive innovation.</p><p dir="ltr">Moreover, RAI Automotive Industry NL recognizes the importance of upskilling and reskilling initiatives in addressing the skills gap. As new technologies emerge, certain skills may become obsolete while new competencies are required. The association’s programs are designed to be flexible and adaptive, allowing professionals to continuously update their skill sets. This approach not only enhances individual career prospects but also strengthens the industry’s overall capability to innovate and compete on a global scale.</p><h2 dir="ltr">Craftsmanship: The Backbone of the Dutch Automotive Industry&nbsp;</h2><p dir="ltr">At the vocational level, craftsmanship remains a critical component of the Dutch automotive sector. Skilled craftsmen and craftswomen are indispensable, providing the hands-on expertise needed to produce innovative automotive solutions. “On the vocational level, craftsmanship is arguably the most important thing that people can develop themselves around,” says Heijster.</p><p dir="ltr">The focus on craftsmanship is supported by initiatives like TALCOM, where vocational training is closely integrated with higher education and industry needs. This integration ensures that vocational graduates possess the practical skills required by the industry, making them valuable assets in the workforce.</p><p dir="ltr">Craftsmanship in the Dutch automotive industry is not just about technical skills; it also encompasses a deep understanding of quality, precision, and innovation. Dutch vocational training programs emphasize these values, ensuring graduates are proficient in their trade and committed to continuous improvement and excellence. This dedication to craftsmanship is reflected in the high-quality products and innovative solutions the Dutch automotive industry is known for globally, especially in the heavy-duty sector and its progression towards sustainability.&nbsp;</p><p dir="ltr">With good zero-emission plans for the heavy-duty sector, the Dutch automotive industry can approach sustainability through zero-emission programs for BEVs, zero-emission programs for FCEVs, and zero-to-low-emission programs for hydrogen ICEs. This will be further enhanced with the new EU rules and legislation requiring the heavy-duty industry to be zero-emission, leading to more opportunities.</p><p dir="ltr">RAI Automotive Industry NL’s emphasis on craftsmanship highlights the broader cultural value placed on vocational education in The Netherlands. Unlike other countries where vocational training may be undervalued, the Dutch approach celebrates and invests in vocational skills, recognizing their crucial role in driving industrial growth and innovation. This cultural appreciation for craftsmanship fosters a sense of pride and commitment among vocational graduates, motivating them to continually hone their skills and contribute to the industry’s success.</p><h2 dir="ltr">Embracing Emerging Technologies: The Hydrogen Economy&nbsp;</h2><p dir="ltr">As the automotive industry transitions towards more sustainable technologies, hydrogen systems are becoming increasingly important. The Green SKHy project exemplifies the proactive steps RAI Automotive Industry NL and its partners took to develop expertise in this area. The project aims to create a European network of hydrogen training labs, providing transnational training schemes to equip professionals with the skills needed for the hydrogen economy.</p><p dir="ltr">The initiative focuses on technical training and careers in the hydrogen sector, thus addressing the industry’s immediate and future needs. It aims to promote the development of the clean hydrogen sector by reducing the obstacles to the European recognition of skills and related systems through joint action plans.</p><p dir="ltr">Hydrogen technology is vital to the future automotive landscape, particularly in the quest for carbon neutrality. The GreenSKHy project supports the European Commission’s hydrogen strategy, which aims to accelerate the development of clean hydrogen as a cornerstone of the EU’s energy system. By training professionals in hydrogen technologies, the project ensures that the automotive industry has the expertise to integrate hydrogen solutions effectively.</p><p dir="ltr">This focus on hydrogen also aligns with broader sustainability goals. Hydrogen-powered vehicles produce zero emissions, making them crucial to the transition to greener mobility solutions. RAI Automotive Industry NL’s involvement in the Green SKHy project demonstrates its commitment to leading this transition, ensuring that the Dutch automotive industry adopts sustainable technologies and pioneers their development and implementation.</p><h2 dir="ltr">Strengthening Industry-Academia-Government Collaboration&nbsp;</h2><p dir="ltr">The collaborative efforts between RAI Automotive Industry NL, ACE Mobility, MBO Automotive Center, and other stakeholders highlight the importance of a unified approach to human capital development. This partnership helps create a future-proof automotive sector through joint initiatives in human capital and technology. It operates at the intersection of industry and automotive education, fostering an environment where skills, knowledge, and expertise are continuously exchanged and enhanced.&nbsp;</p><p dir="ltr">“By combining the deployment of skills, knowledge, and expertise, we can better streamline our joint constituencies in Human Capital and technology programs and projects, among others, and operationalize them through annual plans,” notes Saskia Lavoo, general manager of ACE Mobility.</p><p dir="ltr">This strategic collaboration is not limited to national borders. Both organizations participate in international consortia and represent the Dutch automotive sector at leading trade fairs and congresses.</p><p dir="ltr">Such global engagement ensures that Dutch automotive professionals are exposed to international best practices and emerging trends, further enhancing their ability to innovate and compete on a global scale.</p><p dir="ltr">The partnership between <a href="https://www.acemobility.nl/en/">ACE Mobility</a> and RAI Automotive Industry NL also extends to setting up the Automotive Learning Community, a community focused on the Innovation-LearningWork connection and the National Growth Fund initiatives. These initiatives aim to create a supportive ecosystem for continuous learning and innovation, ensuring that the Dutch automotive industry remains agile and competitive in the face of global challenges.</p><h2 dir="ltr">Dutch Human Capital: A Blueprint for Future Success&nbsp;</h2><p dir="ltr">The Dutch automotive industry’s focus on human capital is a model of excellence, blending continuous education, collaborative innovation, and a commitment to lifelong learning. RAI Automotive Industry NL’s initiatives, from the comprehensive education pipeline to the Triple Helix model, ensure that the sector remains competitive and future-proof. As technological advancements continue to reshape the automotive industry, the Dutch approach to human capital development serves as a blueprint for success, fostering a workforce that is skilled, adaptable, and ready to drive the industry forward.</p><p dir="ltr">The concerted efforts of RAI Automotive Industry NL’s, in collaboration with educational institutions and the government, have created a resilient and dynamic automotive sector. By investing in human capital, The Netherlands is not only addressing the current skills gap but also laying a strong foundation for future innovation and leadership in the global automotive industry. Through initiatives like the Green SKHy project and TALCOM, the Dutch automotive sector is proactively preparing for a sustainable and technologically advanced future.</p><p dir="ltr">For more information, visit our <a href="https://www.raivereniging.nl/en/index/">website</a> and join RAI Automotive Industry NL.</p><p>Learn more about the work of the RAI Automotive Industry NL's members by downloading the full report below.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-242823280704453" title="2024 RAI Dutch Automotive Industry Magazine" allowtransparency="true" src="https://form.jotform.com/242823280704453" frameborder="0" style="min-width:100%;max-width:100%;height:590px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span> </iframe>&nbsp;</span></p>

In an era epitomized by technological advancements and competition in the automotive industry, one value that remains at the core of innovation is human capital. 

Driving Innovation: Human Capital in the Dutch Automotive Industry

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MacroFab's FabIQ aims to disrupt this status quo by leveraging artificial intelligence and a vast database to provide instant, accurate pricing for printed circuit board (PCB) assemblies and panels.

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