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Tag Archive: design concerns

  1. Wire Harness Design Concerns

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    6 Biggest Concerns for Wire Harness Experts

    Wire harness assemblies are an essential component in many electronic products and equipment, and the design process for these assemblies must take into account several important concerns to ensure that the final product is reliable and meets all necessary requirements.

    Proper Routing & Organization

    One of the biggest design concerns for wire harness assemblies is ensuring proper routing and organization of the wires and cables. The harness must have the wires and cables properly routed and arranged to prevent any damage, wear, and tear and also to prevent any interference between the different wires. The routing also has to take into consideration the physical constraints of the application and avoid any possible stress points or areas that may cause damage over time.

    Material & Connector Selection

    Another concern is selecting the correct materials for the wires and cables. The materials must be suitable for the intended application and environment and must be able to withstand the conditions to which the harness will be exposed. This includes factors such as temperature, humidity, mechanical stress, and exposure to chemicals or other environmental factors.

    A related concern is the connector selection, which is an important part of wire harness design. The connectors must be compatible with the wires and cables and must meet the requirements of the specific application, including factors such as temperature, humidity, and vibration. It is also important to choose connectors that are easy to install and maintain, to minimize downtime and maintenance costs.

    Labeling, Marking, Tracing…Oh My!

    Another important design concern is the use of proper labeling, markers, and traceability codes. The harness must be clearly labeled to allow for easy identification of each wire and its corresponding connector, as well as traceability codes, to be able to identify where each part of the harness comes from and when it was produced. Proper labeling is also critical for maintaining compliance with industry regulations and standards.

    Durable Design

    Designing a wire harness assembly that can withstand the rigors of production, transportation, and the intended application is also a significant concern. This includes things like ensuring that the harness is durable and resistant to wear and tear and that the wires and cables are properly secure to prevent them from becoming loose or disconnected.

    Test the Limits

    Additionally, proper testing and validation are key concerns, to ensure that the wire harness assembly meets the specifications and requirements of the application. The harness assembly must ensure that all the connections are secure, that there are no open or short circuits, and that all the wire connections are proper.

    What’s the Cost?

    Finally, the cost is always a concern when designing a wire harness assembly. The cost of materials and components can add up quickly, and it’s important to minimize costs by using the most cost-effective materials and components.

    To avoid any mistakes with your wire harness assembly, utilize PGF Technology Group for manufacturing. To learn more about our wire harness capabilities, visit this page!

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  2. 6 Common Design Concerns with PCBAs

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    Before PGF, There’s the Design

    Designing a Printed Circuit Board Assembly (PCBA) can be a complex task, and engineers must take into account many concerns to ensure that the assembly functions correctly and meets all the requirements. These concerns include everything from the layout and routing of the circuits to the selection of components and materials. Before starting with the PGF partnership, a company must first solidify its design for the assembly process. 


    1. Proper Routing

    One of the most important design concerns in PCB Assembly is ensuring the proper routing of the circuits. This means that the pathways for electrical current are clear and free of any obstacles that could cause a short circuit or other problems. The routing of the circuits must also take into account the power requirements of the components, as well as any potential electromagnetic interference (EMI) that could affect the functioning of the assembly.


    2. Layout of Components

    Another important design concern is the layout of the components on the PCBA. Engineers must carefully consider the placement of the components to ensure easy assembly and enough space for them to function properly. The layout must also take into account the thermal characteristics of the components, as some components may generate more heat than others, and the layout should dissipate this heat effectively.


    3. Component Selection

    Component selection is also an important design concern. Chosen components must be appropriate for the application and compatible with the PCBA. This designation includes not only electronic components but also the materials used on PCBAs such as the substrate, copper thickness, solder mask, etc. Engineers should select them based on their specifications and characteristics, such as power dissipation and operating temperature range, and should be of good quality to ensure that they function correctly and have a long service life.


    4. Safety and Compliance Requirements

    The PCB Assembly must meet any necessary safety and compliance requirements. PCBAs in medical devices, for example, must meet stringent safety and performance standards set by certifications such as ISO 13485:2016. This includes ensuring that the materials and components in the assembly are safe for use in a medical environment and that the assembly is properly shielded to protect against electromagnetic interference. Similarly, PCBAs used in other applications such as industrial or aerospace must meet relevant compliance and safety standards.


    5. Testing and Validation

    Another important design concern is testing and validation of the PCB Assembly. The functionality of the PCB Assembly must be verified through various testing methods such as visual inspection, continuity testing, in-circuit testing, and functional testing to ensure that it meets the specifications and requirements of the application. Some machines to assist with the testing process include X-ray and AOI Inspection. This testing must happen at different stages of the assembly process to ensure the early detection and correction of any problems.


    6. Cost

    Finally, the cost is always a concern when designing a PCB Assembly. PCBAs can be expensive to manufacture, and the cost of components and materials can add up quickly. To minimize costs, the designer must consider the most cost-effective components and materials and use them in the assembly. Additionally, the design should be optimized to minimize the number of components and the size of the PCBA, while still meeting all the requirements.



    In conclusion, designing a Printed Circuit Board Assembly involves many design concerns that need to be taken into account. Proper routing and layout of circuits, component selection, safety and compliance, testing and validation, and cost are key design concerns that engineers need to address to ensure that the PCB assembly functions correctly and meets all requirements. Skilled engineers and designers with experience in PCBA design and assembly can help to confirm functionality and feasibility before starting with your contract manufacturer. At PGF, you design it, and we’ll build it! 

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