# New PCB Assembly Method Promises Higher Reliability & Lower Cost

- Show: [OnTrack](https://hardwarepodcasts.com/podcast/ontrack)
- Published: 2025-09-30
- Length: 36m
- Episode: 313
- Page: https://hardwarepodcasts.com/podcast/ontrack/2025-09-30-new-pcb-assembly-method-promises-higher-reliability-lower-cost
- Listen: https://podcast.altium.com/e/new-pcb-assembly-method-promises-higher-reliability-lower-cost/

## Summary

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.

## Chapters

- [0:00](https://hardwarepodcasts.com/podcast/ontrack/2025-09-30-new-pcb-assembly-method-promises-higher-reliability-lower-cost#t=0) Introduction: Ray Rasmussen and The Occam Group
- [1:47](https://hardwarepodcasts.com/podcast/ontrack/2025-09-30-new-pcb-assembly-method-promises-higher-reliability-lower-cost#t=107) Rasmussen's Background and Entry into the Occam Process
- [7:19](https://hardwarepodcasts.com/podcast/ontrack/2025-09-30-new-pcb-assembly-method-promises-higher-reliability-lower-cost#t=439) The Occam Methodology: Embedded Components and Copper-to-Copper Connections
- [11:01](https://hardwarepodcasts.com/podcast/ontrack/2025-09-30-new-pcb-assembly-method-promises-higher-reliability-lower-cost#t=661) DOD Testing and Comparison with Conventional PCBs
- [17:48](https://hardwarepodcasts.com/podcast/ontrack/2025-09-30-new-pcb-assembly-method-promises-higher-reliability-lower-cost#t=1068) Industry Standards, Data Gaps, and Funding Challenges
- [20:19](https://hardwarepodcasts.com/podcast/ontrack/2025-09-30-new-pcb-assembly-method-promises-higher-reliability-lower-cost#t=1219) Supply Chain Implications and US Manufacturing Reshoring
- [24:16](https://hardwarepodcasts.com/podcast/ontrack/2025-09-30-new-pcb-assembly-method-promises-higher-reliability-lower-cost#t=1456) Semiconductor Integration and Signal Integrity Benefits
- [28:54](https://hardwarepodcasts.com/podcast/ontrack/2025-09-30-new-pcb-assembly-method-promises-higher-reliability-lower-cost#t=1734) EMS Resistance and the Path to Market Adoption

## Topics

- [PCB design & layout](https://hardwarepodcasts.com/topic/pcb-design)
- [Manufacturing partners & offshoring](https://hardwarepodcasts.com/topic/manufacturing-partners)
- [Sourcing & supply chain](https://hardwarepodcasts.com/topic/sourcing-and-supply-chain)
- [Quality & yield](https://hardwarepodcasts.com/topic/quality-and-yield)

## Most relevant to

early-stage companies

## Mentioned

- The Occam Group (company)
- Joe Felstadt (other)
- Denny Fritz (other)
- Dana Korf (other)
- Tessera (company)

## Related episodes from other shows

- [322: Learn Assembly Code](https://hardwarepodcasts.com/podcast/embedded-fm/2020-02-28-322-learn-assembly-code) (Embedded.fm)
- [Building Together: Oxide and Samtec](https://hardwarepodcasts.com/podcast/oxide-and-friends/2023-05-16-building-together-oxide-and-samtec) (Oxide and Friends)
- [407: Boards Are Like Sandwiches](https://hardwarepodcasts.com/podcast/embedded-fm/2022-03-24-407-boards-are-like-sandwiches) (Embedded.fm)
- [PCB Assembly and Design for Manufacturing with Duane Benson of Screaming Circuits](https://hardwarepodcasts.com/podcast/predictable-designs-podcast/2020-03-03-pcb-assembly-and-design-for-manufacturing-with-duane-benson-of-screaming-circuit) (Predictable Designs Podcast)
- [Bob Widlar, Electronic Design, FIRST Robotics - Monday, Meta Monday](https://hardwarepodcasts.com/podcast/the-amp-hour/2011-03-08-bob-widlar-electronic-design-first-robotics-monday-meta-monday) (The Amp Hour)

## Citing this page

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