Hardware Podcasts

New PCB Assembly Method Promises Higher Reliability & Lower Cost

OnTrack · 30 Sept 2025 · 36m · Episode 313

What this episode covers

Ray Rasmussen, Managing Partner at The Occam Group, explains a novel PCB assembly methodology that eliminates solder by embedding components and building copper-to-copper connections using existing factory equipment. He contrasts this low-capital approach with the massive investments required for traditional high-density interconnects, highlighting its potential to strengthen US manufacturing supply chains. The discussion covers ongoing Department of Defense testing in Crane, Indiana, which compares conventional boards to Occam assemblies for reliability and performance metrics. Rasmussen notes that while EMS providers are hesitant due to thin margins, semiconductor partners see significant signal integrity benefits, positioning Occam as a pathway for US fabricators to compete globally without new capital expenditure.

Most relevant to

early-stage companies

Topics

Mentioned

Companies
The Occam Group, Tessera
Also
Joe Felstadt, Denny Fritz, Dana Korf

Related episodes from other shows

Other shows on the same ground, closest first.

  • Embedded.fm · 57m

    322: Learn Assembly Code

    Ramiro Montes de Oca, CEO and founder of aThing.io, explains his company's 'motionless electronics'—modular, penny-sized components that connect via phone-style connectors without soldering. He discusses the technical architecture of these modules, the emerging chiplet industry standard led by the Chiplet Alliance, and the business challenges of scaling hardware manufacturing during global supply chain disruptions. Montes de Oca also shares insights from exhibiting at CES and the importance of design-for-manufacturing for early-stage founders.

    PCB design & layoutChips, FPGAs & semiconductors
    8 chapters

  • Oxide and Friends · 1h 20m

    Building Together: Oxide and Samtec

    Bryan Cantrill and Adam Leventhal of Oxide Computer Company discuss their partnership with Samtec, featuring guests Jonathan Ghesh and Jignesh Khanna, to build the Oxide Rack using flyover cable systems instead of traditional PCB backplanes. Ariane Goldstein explains how this architecture allowed for modular board design, thermal management, and rapid iteration, while Jignesh details the technical challenges of signal integrity, cable manufacturing, and the shift toward copper over optics. The conversation highlights Samtec's 'Sudden Service' model, where deep engineering collaboration and onshore manufacturing in the US enabled Oxide to solve critical failure modes, such as solder joint cracking, through joint problem-solving rather than adversarial vendor relationships.

    PCB design & layoutManufacturing partners & offshoring
    10 chapters

  • Embedded.fm · 1h 01m

    407: Boards Are Like Sandwiches

    Mihir Shah, CEO of Royal Circuits and former CEO of InspectAR, explains the complex, labor-intensive manufacturing process of printed circuit boards (PCBs), detailing how they are built from the inside out using lithography and chemical etching. He discusses the consolidation of the US PCB industry, noting that high capital expenditures for equipment have driven out smaller shops, leaving a fragmented market dominated by a few large players. Shah also outlines Royal Circuits' corporate venture strategy, investing in early-stage hardware and software startups like SnapEDA and Illuminant Surgical to support the engineering community.

    PCB design & layoutManufacturing partners & offshoring
    9 chapters

  • Predictable Designs Podcast · 1h 01m

    PCB Assembly and Design for Manufacturing with Duane Benson of Screaming Circuits

    Duane Benson, Director of Marketing at Screaming Circuits, explains the PCB assembly process, contrasting their prototype/small-volume model with parent company Milwaukee Electronics' high-volume contract manufacturing. He details the workflow from programming and solder paste deposition to reflow, inspection, and rework, while highlighting common Design for Manufacturing (DFM) pitfalls like open vias and incorrect QFN footprints. The discussion covers the infeasibility of home PCB prototyping, the cost-benefits of US-based assembly, and critical tips for ensuring component availability and accurate footprints.

    PCB design & layoutManufacturing partners & offshoring
    10 chapters

  • The Amp Hour · 1h 03m

    Bob Widlar, Electronic Design, FIRST Robotics - Monday, Meta Monday

    Hosts Chris Gammell and Dave Jones discuss format changes to The Amp Hour, including the potential removal of Workbench of the Week and the introduction of sponsorship. They review low-cost PCB manufacturing from IT'd Studio, noting the $12 fixed-price service for small boards, and discuss the logistics of automated assembly. The conversation also covers the FIRST Robotics competition, Bob Widlar's legacy, and the value of practical engineering education over pure theory.

    PCB design & layoutManufacturing partners & offshoring
    6 chapters

The summary, chapters and topics are generated from the episode’s audio by this directory, not written by OnTrack. The episode itself belongs to its publisher.