The Spark Gap - Episode 27

The Spark Gap · 25 Feb 2015 · 38m

What this episode covers

Hosts Carl and Corey share embedded electronics horror stories, including Corey’s PCB layout error where a tool connected line and neutral, and Carl’s experience with a potato gun fireball. They discuss common design pitfalls such as incorrect through-hole sizing, voltage level mismatches between an FPGA and a 1.8V chip, and the leakage currents of unpowered ICs like FTDI chips. The conversation emphasizes the importance of reading datasheets, verifying Gerber files, and understanding power-up sequencing to avoid bricking components or causing shorts.

Other shows on the same ground, closest first.

  • The Amp Hour

    Your Mind Is The Tool

    Chris Gammell and Dave Jones discuss troubleshooting a dead short in a PCB where a manufacturer modified Gerber files, causing a via to be placed on the wrong layer. They analyze why standard e-test fails to catch such errors and debate whether two-layer PCBs are sufficient for complex designs, referencing tools like KiCad and JLC. The conversation shifts to Dave Jones's decision to stop designing his own products, citing the high NRE costs, lack of discipline in solo projects, and the competitive advantage of rebranding existing hardware. They also touch on industry news, including the retirement of Jack Gansell and the passing of BBS inventor Ward Christensen.

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    This Is Just A Tribute

    Chris Gammell discusses his new video podcast, The Contextual Electronics Podcast, and details a Gerber file resolution error he encountered with JLCPCB while designing the ABC board. Dave Jones explains the technical nuances of Gerber resolution and aperture settings, while both hosts analyze the industry implications of ARM being up for sale, Intel's manufacturing struggles, and Google's new $300 engineering certification program.

  • The Amp Hour · 1h 14m

    Assembly Chat

    Hosts Dave Jones and Chris Gammell record an episode while Dave assembles a PCB, discussing the utility of the Interactive BOM plugin for KiCad and the board repair software by Paul Daniels. They identify design flaws in Dave's board, including incorrect capacitor voltage ratings and missing silkscreen designators, and share technical tips on reliability, such as using series capacitors to prevent short circuits. The conversation also covers battery selection for cold environments, the OWASP Top 10 for hardware security, and vintage test equipment.

  • Predictable Designs Podcast · 16m

    Top 10 Product Design Mistakes You Must Avoid

    John Teal, founder of Predictable Designs and former Texas Instruments chip designer, outlines ten critical product design mistakes for electronic hardware startups. He covers technical errors such as incorrect RF impedance matching, insufficient PCB trace width for high currents, and poor switching regulator layout, alongside process failures like neglecting Design for Manufacturing (DFM) and delaying cost estimation. Teal emphasizes the importance of independent design reviews and proper via selection to avoid costly prototype iterations and manufacturing issues.

  • OnTrack · 39m

    PCB Assembly Mistakes Designers Keep Making: PCB West 2026 Preview

    Zach Peterson hosts Mike Buetow (PCEA), Chrys Shea (Shea Engineering), and Daniel Stanphill (Aurora Boardworks) to preview the circuit assembly track at PCB West 2026. The panel discusses common PCB design-for-manufacturing mistakes, such as using unvalidated datasheet footprints and ignoring padstack constraints, and highlights advanced assembly technologies like placing 2 kg components and 006003 passives. They also cover the importance of networking, talent acquisition, and understanding solder paste and stencil design for successful production.

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