# The Spark Gap - Episode 40

- Show: [The Spark Gap](https://hardwarepodcasts.com/podcast/the-spark-gap)
- Published: 2015-10-03
- Length: 1h 11m
- Page: https://hardwarepodcasts.com/podcast/the-spark-gap/2015-10-03-the-spark-gap-episode-40
- Listen: https://thesparkgap.net/the-spark-gap-episode-40

## Summary

Hosts Carl and Corey discuss the design gotchas of electronic connectors, covering power inputs like barrel jacks and screw terminals, as well as signal interfaces including ribbon cables and board-to-board connectors. They highlight specific risks such as contact resistance, voltage breakdown in high-density connectors, and the importance of pin sequencing for power rails. The conversation also covers practical PCB layout advice, including the use of 3D models to verify mechanical fit and the thermal limitations of surface-mount components during reflow.

## Chapters

- [0:00](https://hardwarepodcasts.com/podcast/the-spark-gap/2015-10-03-the-spark-gap-episode-40#t=0) Introduction and Part of the Podcast: LM7705 and VNC2
- [17:13](https://hardwarepodcasts.com/podcast/the-spark-gap/2015-10-03-the-spark-gap-episode-40#t=1033) Power Connectors: Barrel Jacks and Screw Terminals
- [24:26](https://hardwarepodcasts.com/podcast/the-spark-gap/2015-10-03-the-spark-gap-episode-40#t=1466) Connector Durability, Contact Resistance, and Surface Finish
- [33:08](https://hardwarepodcasts.com/podcast/the-spark-gap/2015-10-03-the-spark-gap-episode-40#t=1988) High Voltage, Pin Sequencing, and Ribbon Cable Pitfalls
- [48:40](https://hardwarepodcasts.com/podcast/the-spark-gap/2015-10-03-the-spark-gap-episode-40#t=2920) Mechanical Fit, 3D Modeling, and Reflow Risks
- [1:02:31](https://hardwarepodcasts.com/podcast/the-spark-gap/2015-10-03-the-spark-gap-episode-40#t=3751) Mid-plane Connectors, Tombstoning, and High-Speed Signal Integrity

## Topics

- [PCB design & layout](https://hardwarepodcasts.com/topic/pcb-design)
- [Materials & manufacturing processes](https://hardwarepodcasts.com/topic/materials-and-processes)
- [Debugging & failure analysis](https://hardwarepodcasts.com/topic/debugging-and-failure-analysis)

## Most relevant to

makers and hobbyists

## Mentioned

- LM7705 (chip)
- VNC2 (chip)
- FTDI (company)
- Altium (tool)
- KiCad (tool)
- Eagle (tool)

## Related episodes from other shows

- [High Power PCB Design: Pushing the Limits with Caleb Buck](https://hardwarepodcasts.com/podcast/ontrack/2025-08-19-high-power-pcb-design-pushing-the-limits-with-caleb-buck) (OnTrack)
- [Call In Show #3](https://hardwarepodcasts.com/podcast/the-amp-hour/2016-02-26-call-in-show-3) (The Amp Hour)
- [Assembly Chat](https://hardwarepodcasts.com/podcast/the-amp-hour/2021-10-11-assembly-chat) (The Amp Hour)
- [PCB Connectors That Survive Space, Shock & 500 Thermal Cycles](https://hardwarepodcasts.com/podcast/ontrack/2026-10-07-pcb-connectors-that-survive-space-shock-500-thermal-cycles) (OnTrack)
- [Ep 313: Capacitor Plague, Wireless Power, and Tiny Everything](https://hardwarepodcasts.com/podcast/hackaday-podcast/2025-03-21-ep-313-capacitor-plague-wireless-power-and-tiny-everything-cb8186ab) (Hackaday Podcast)

## Citing this page

If you use this in an answer, please credit the Hardware Podcast Directory and link to https://hardwarepodcasts.com/podcast/the-spark-gap/2015-10-03-the-spark-gap-episode-40. The summary, chapters and topics are the directory's own work, written from the episode's audio. The episode itself, its title and its audio belong to The Spark Gap.