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Engineering Blog

Practical guides for working engineers — no fluff, real numbers.

PCB DesignAug 18, 20264 min read

Annular Ring: Why the Pad Is Bigger Than You Drew It

A 0.3 mm drill does not give you a 0.3 mm hole, and the pad around it has to absorb drill wander, registration error, and plating build-up. Here is where each of those numbers comes from and why IPC-6012 Class 3 costs more.

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PCB DesignAug 18, 20264 min

BGA Escape Routing Starts at the Land Pad

How many traces fit between two BGA balls is decided the moment you pick the pad diameter. Here is the arithmetic from pitch to channel width to trace count, and why NSMD and via-in-pad change the answer.

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PCB DesignAug 18, 20264 min

How Much Current Can a Microvia Carry?

A 100 µm microvia has a fifth the copper of a through-hole via and a fraction of its resistance. The IPC-2221 current formula gives two different answers depending on a constant nobody can definitively pick — and neither is what actually fails.

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PCB DesignAug 16, 20264 min

How Much Current Melts a PCB Trace?

Onderdonk's equation was derived for round wire in 1928. Applying it to PCB traces requires knowing the actual cross-section — which isn't rectangular after etching. Here's the physics, the geometry correction, and why the answer is less conservative than you'd hope.

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PCB DesignAug 16, 20264 min

Mils, Millimetres, and the PCB Unit Mess

PCB design lives in two unit systems simultaneously. Copper weight is oz/ft squared, drill sizes are in mils, board dimensions are in millimetres, and IPC tables mix all three. Here's the conversion logic and the one constant worth memorising.

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Signal IntegrityAug 16, 20264 min

When a Trace Becomes a Transmission Line

Every trace is a transmission line at some frequency. The critical length threshold tells you whether your particular trace at your particular edge rate needs controlled impedance or not. The answer depends on two numbers and a judgment call.

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