# Chatting Ultra HDI: Chrys Shea, PCB Miniaturization & Challenges Ahead

- Show: [OnTrack](https://hardwarepodcasts.com/podcast/ontrack)
- Published: 2024-04-02
- Length: 47m
- Episode: 260
- Page: https://hardwarepodcasts.com/podcast/ontrack/2024-04-02-chatting-ultra-hdi-chrys-shea-pcb-miniaturization-challenges-ahead
- Listen: https://podcast.altium.com/e/chatting-ultra-hdi-chrys-shea-pcb-miniaturization-challenges-ahead/

## Summary

Chrys Shea, President of Shea Engineering, explains the design and utility of advanced test vehicles for Ultra High-Density Interconnect (UHDI) assembly, focusing on challenges like the leading edge effect and tombstoning. She details how her latest board quantifies solder paste variation and tests off-axis placement, while also addressing Surface Insulation Resistance (SIR) and the trade-offs of using minimum IPC pad sizes. The discussion highlights the importance of early DFM collaboration between designers and assemblers to mitigate defects like tombstoning and mask misregistration in high-volume manufacturing.

## Chapters

- [0:00](https://hardwarepodcasts.com/podcast/ontrack/2024-04-02-chatting-ultra-hdi-chrys-shea-pcb-miniaturization-challenges-ahead#t=0) Introduction: Chrys Shea and Shea Engineering
- [2:55](https://hardwarepodcasts.com/podcast/ontrack/2024-04-02-chatting-ultra-hdi-chrys-shea-pcb-miniaturization-challenges-ahead#t=175) Evolution of the Solder Paste Test Vehicle
- [5:41](https://hardwarepodcasts.com/podcast/ontrack/2024-04-02-chatting-ultra-hdi-chrys-shea-pcb-miniaturization-challenges-ahead#t=341) UHDI Challenges: Density and Pad Sizes
- [11:47](https://hardwarepodcasts.com/podcast/ontrack/2024-04-02-chatting-ultra-hdi-chrys-shea-pcb-miniaturization-challenges-ahead#t=707) New Test Vehicle: Off-Axis Placement and Leading Edge Effect
- [19:31](https://hardwarepodcasts.com/podcast/ontrack/2024-04-02-chatting-ultra-hdi-chrys-shea-pcb-miniaturization-challenges-ahead#t=1171) Daisy Chains, Thermal Cycling, and Microvia Testing
- [24:18](https://hardwarepodcasts.com/podcast/ontrack/2024-04-02-chatting-ultra-hdi-chrys-shea-pcb-miniaturization-challenges-ahead#t=1458) Surface Insulation Resistance (SIR) and Fabrication Tests
- [30:34](https://hardwarepodcasts.com/podcast/ontrack/2024-04-02-chatting-ultra-hdi-chrys-shea-pcb-miniaturization-challenges-ahead#t=1834) Tombstone Alley and Defect Analysis
- [35:07](https://hardwarepodcasts.com/podcast/ontrack/2024-04-02-chatting-ultra-hdi-chrys-shea-pcb-miniaturization-challenges-ahead#t=2107) DFM: Mask Misregistration and Designer-Assembler Collaboration

## Topics

- [PCB design & layout](https://hardwarepodcasts.com/topic/pcb-design)
- [Design for manufacturing & NPI](https://hardwarepodcasts.com/topic/design-for-manufacturing)
- [Quality & yield](https://hardwarepodcasts.com/topic/quality-and-yield)
- [Manufacturing partners & offshoring](https://hardwarepodcasts.com/topic/manufacturing-partners)

## Most relevant to

early-stage companies

## Mentioned

- Shea Engineering (company)
- Altium (company)
- SMTA (other)
- ASC (company)
- Calumet (company)
- ASMPT (company)

## Related episodes from other shows

- [I've bitten myself](https://hardwarepodcasts.com/podcast/the-amp-hour/2018-05-21-ive-bitten-myself) (The Amp Hour)
- [Chris Denney | PCB Design, Fabrication, & Manufacturing](https://hardwarepodcasts.com/podcast/being-an-engineer/2022-12-16-chris-denney-pcb-design-fabrication-manufacturing) (Being an Engineer)
- [Raiding the Minibar](https://hardwarepodcasts.com/podcast/oxide-and-friends/2025-04-01-raiding-the-minibar) (Oxide and Friends)
- [S7E2 WEBINAR: Your Manufacturer is Stupid: Why Your Circuit Board Design Is Making Their Job Harder with Chris Denney](https://hardwarepodcasts.com/podcast/being-an-engineer/2026-01-09-s7e2-webinar-your-manufacturer-is-stupid-why-your-circuit-board-design-is-making) (Being an Engineer)
- [Compact High Speed Design with Lukas Henkel](https://hardwarepodcasts.com/podcast/the-amp-hour/2024-10-31-compact-high-speed-design-with-lukas-henkel) (The Amp Hour)

## Citing this page

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