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Before the pandemic, conflict in Ukraine, and trade tension with China, supply chain risk management was a topic that mostly interested eager business students and industry scholars. Back then, most businesses didn’t have to contend with much risk in supply chains, and rarely worried about delays or shortages of needed parts.

Then came the pandemic and its aftermath, and along with it, broken supply chains. And those supply chains that didn’t break still strained to deliver raw materials and other inputs. The most visible sector to be hit by these shortages was the automotive industry. S&P Global Mobility estimated that there were 9.5 million fewer light vehicles produced in 2021 because of the lack of semiconductors. But the electronics industry—though it didn’t make the same headlines—also suffered. And those shortages have had a lasting effect.

No Return to the Status Quo for Supply Chain Risk Management

Savvy manufacturers are recognizing that preparation is the key to flexibility, and are creating contingency plans and crisis-response infrastructures that enable them to better manage supply chain risks.

Compared to their predecessors, today’s electronic devices are chip hogs. So while semiconductor manufacturers continue to ramp up capacity, especially here in the U.S., some electronics companies still find themselves redesigning products to make use of more readily available components. It’s this type of scenario that makes supply chain risk management more than just an academic exercise.

It’s highly unlikely that supply chain risk management will ever return to the business-as-usual approach of the pre-pandemic years. Industry leaders surveyed for a recent McKinsey & Company report made it clear they have no intention of returning to the status quo ante. New trends and approaches are now emerging in response to lessons learned during the pandemic years.

Trend #1: The Shift from “Just-in-Time” to “Just-in-Case”

Electronics companies have long pursued efficiency and cost-reduction strategies, and were early adopters of “just-in-time” manufacturing when the concept arrived on America’s shores in the early ‘80s. For many years, companies competed to see how far they could push this lean manufacturing model in their quest to eliminate waste, and some began carrying very low parts inventories. By reducing the number of components sitting in their warehouses, these companies were able to minimize storage costs, maximize efficiency, and reap higher profits. It was a flawless system—provided there were no disruptions.

A young woman in hardhat and safety vest, holding a clipboard and standing in front of shelves holding electronics components
Just-in-time manufacturing is giving way to a just-in-case approach.

However, this lean-and-mean model was vulnerable to hiccups. That wasn’t a problem when supply disruptions were few and far between. But then the pandemic came, and the dominos began to fall. China adopted a zero-covid policy and closed ports when there was an outbreak, disrupting chip supplies the world over. Then came the Ukraine-Russia war, which disrupted global supplies of neon (used in chipmaking lasers) along with palladium, cobalt, and nickel.

As a result of these and other disruptions, electronics manufacturers found themselves scrambling for new suppliers, and sometimes, even redesigning their products to rely on more readily available components. These companies had bumped up against a non-negotiable reality: Lean manufacturing practices, while ideal during times of robust supply chains, sacrifice resilience for efficiency. And supply chains are no longer as reliable as they once were.

After being burned by the “just-in-time” approach in the last few years, many companies are now shifting to a new strategy: the “just-in-case” model. Keeping extra materials on hand costs more and can lead to excess stock or obsolescence. However, many companies today are accepting these risks to offset the chance they will experience severe shortages. Despite the elevated costs of this new approach, experts anticipate that companies will continue to follow this path for at least a few more years, unless and until global supply chains stabilize.

Now the pressing question for electronics companies is: How many component parts should they keep on hand? And how best to manage that inventory? This is one reason why it’s increasingly important to work with a manufacturing partner with expertise in supply chain management and inventory control.

Trend #2: Bringing Manufacturing Back to America

The just-in-time approach was not the only strategy that made companies vulnerable when supply chain disruptions hit. Many American companies sourced from the Far East—an approach that quickly became problematic during global disruptions. Sourcing so far from their primary markets left little leeway for error, and many companies faced huge shipment delays—first in Asia, then in Europe, and then in regions of South America. Country-specific tax and trade regulations added to shipping timeline woes, slowing delivery of much-needed parts. Budget concerns also plagued companies as international shippers dramatically increased prices. For example, during the pandemic, the cost of shipping a forty-foot container rose from about $1,300 to more than $11,000, before returning to its current average of about $4,000.

The cost of shipping a forty-foot container has dropped from its pandemic high, but still averages about $4,000.

As these circumstances unfolded, American companies began seeking ways to reduce exposure to supply chain risk. Many businesses began exploring their options for doing business closer to home. According to the BCI Supply Chain Resilience Report 2020, 66.2% of organizations reported planning to source their goods and inputs more locally.

In addition to timing and budget concerns, companies have faced other challenges: rising labor costs worldwide, growing political instability in certain exporting countries, and trade wars that result in unpredictable tariff increases. These disruptive developments are leading many companies to rethink their global manufacturing strategies and seek reshoring partners.

Another reason many U.S. manufacturers are seeking to source and build closer to home is the threat of intellectual property (IP) theft. Chinese manufacturing partners are generally considered the riskiest in this regard. According to the U.S. Patent and Trademark Office (USPTO), “U.S. companies doing business in China face a range of challenges in protecting and enforcing their intellectual property (IP).” But while China may be the most well-known country in this regard, IP theft is a global phenomenon, making domestic production the safest option for IP protection.

Trend #3: Flexibility and Preparation Become Critical

The overwhelming majority of respondents in the above-referenced McKinsey report said that recent global crises have revealed weaknesses in their supply chains. One of those weaknesses was relying on a sole supplier, an approach that many manufacturers have begun to rethink. According to a survey conducted the Cybersecurity and Infrastructure Security Agency (CISA), 57.2% of respondents planned to diversify their supplier base post-pandemic.

Manufacturers have also recognized that they can reduce supply chain risk if their PCBA designs are more flexible; that is, if they can use the same components for multiple functions, or conversely, use different components to achieve the same result.

Savvy manufacturers are also recognizing that preparation is the key to flexibility, and so are creating contingency plans and crisis-response infrastructures that enable them to better manage supply chain disruptions. These forward-thinking businesses have planned for a wide variety of “what-if” scenarios, with the goal of compensating for material shortages and distribution bottlenecks without missing a beat.  

Trend #4: Optimizing Inventory and Distribution Technology

Taking advantage of current technology is critical for optimizing the end-to-end management of any supply chain. Respondents in the McKinsey report saw an urgent need to gain better control of their supply-chain technology, a goal which will require a skilled workforce trained to use new digital tools. It’s not surprising that 90% of industry leaders surveyed said they planned to increase their organizations’ supply chain talent through in-house reskilling and external hires.

Another way companies are choosing to optimize their supply chain operations is by increasing supply chain visibility and control through the Industrial Internet of Things (IIoT) and other technologies. For example, automating the warehouse, back office, and transportation network allows a company to know precisely when its components and other inputs arrive and in what condition. And it lets these same companies monitor where their finished products are in transit, when the customer receives them, and in what condition. A relatively new IIoT technology, known as Multi-Dimensional Monitoring (MDM) can provide real-time tracking that generates notifications for all stakeholders along the supply chain.

Every new advance has its tradeoffs, however. While increased automation does enable electronics companies to better manage both material inputs and finished products, this same technology also brings an increased risk of malware, ransomware, phishing, hacking, and data breaches. Cyberthreats have grown steadily over the past few years, and these threats escalated as businesses connected their systems directly to their growing base of suppliers.

According to CyberGRX, a cybersecurity management company, 82% of organizations have experienced one or more data breaches caused by a third party—at an average cost of $7.5 million per incident. Any vendor that interacts with your systems is a risk. The answer, however, is not a return to clipboards and hand counting. Rather, companies should carefully vet their suppliers—not just to make sure those suppliers are trustworthy, but also to ensure that these vendors’ systems are as hack-proof as possible. It’s prudent to remember that vendor systems that connect to your company network are in a sense part of your network—and your cybersecurity is only as robust as the weakest link.

Trend #5: Looking Beyond Supply Chain Risk Management

Managing a company’s supply chain isn’t simply about risk mitigation. As more and more companies are discovering, it’s possible to use the supply chain to achieve secondary, yet highly valuable, goals. Companies seeking to up their ESG score, for example, can use their supply chain to promote both diversity and sustainability, simply by considering these factors in choosing their vendors. If your vendor has a high ESG score, it can help increase your own.

Quality, efficiency, reliability, and cost-effectiveness will always be a company’s primary considerations. Fortunately, however, these days there are many suppliers that can deliver on these requirements along with the diversity and sustainability you need to help you meet your own ESG goals. So be sure to ask about these issues when vetting your suppliers. With just a little extra effort, your company will be able to meet its ESG goals while effectively addressing supply chain risk management.

An Electronics Manufacturing Partner You Can Rely On

At PRIDE Industries, we help companies increase profits by stabilizing their supply chain. Our state-of-the-art facilities minimize your risk of disruption, optimize manufacturing and fulfillment processing, and provide flexible, on-demand inventory schedules. And our inclusive workforce—about 50% of our employees have a disclosed disability—means that working with us also allows you to make a positive social impact with your business spend, while meeting consumer demand for products made in the U.S.A.
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The holy grail of contract electronics manufacturing is Design for Manufacturability (DFM). To better understand this constantly evolving discipline, Reliability Matters host Mike Konrad invited Director of Product Engagement Andrew Williams—a sought-after lecturer on DFM, DFT, and DFS topics—to talk circuit assembly best practices on his podcast.

Are you ready to partner with a contract electronics manufacturer that can help you design for excellence?
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It happens instantaneously. And if it doesn’t, the consequences range from vaguely annoying to downright alarming. When we touch a screen, drive a car, or use a critical medical device, we expect and rely on instant responses, generated in fractions of a second, for our entertainment and—more and more—our health and safety. And because of the vital role that electronic devices have in our lives, electronics testing and inspection can literally be a matter of life or death. As melodramatic as that sounds, the reality is when it comes to our reliance on electronic devices, rigorous testing of their PCB brains is critical to prevent failures and increase quality.

While it’s easy to see the importance of electronics testing, the question is: When bringing an electronic product to market, what are the tests and inspections you should discuss with your contract manufacturer? Having some insight into what the key tests are can be helpful. So, let’s take a more detailed look at the tests and inspections that electronic devices need to go through.

Devising the best testing strategy will mean working with a manufacturing partner experienced in both DFM and DFT.

What Electronics Testing Will My Product Need?

Although there is value to every test, not every test will be suitable for your product. The when-and-what of testing will depend on several factors, such as the product’s function, user environment, and production volume. The key to success is implementing strategic, device-specific testing that provides thorough quality control, while allowing for streamlined and efficient assembly and production.

The primary uses of the device you want to bring to market will naturally influence electronics testing. A consumer product that sits on a shelf will not encounter the same conditions as a device for the medical or aerospace industry. Electronics subject to harsher environments require stringent test protocols that will challenge stress limits and therefore ensure reliability.

Another consideration is the product’s stage of development. In the prototyping stages, functional and design verification tests are essential for identifying technical flaws and refining the product’s features. The small-batch nature of prototyping, especially rapid prototyping, will inevitably mean different test considerations. While cost-effective at mass production, the expense of some test setups is just not viable for small runs.

Devising the best testing strategy will mean working with a manufacturing partner experienced in design for manufacturability (DFM) and design for test (DFT). An electronics manufacturing services (EMS) provider who understands your priorities can ensure pertinent tests and inspections are conducted to refine the board for optimum safety, quality, and production.

What kind of electronics testing will ensure optimal performance and reliability for your particular product? Here are five of the most robust testing technologies to consider.

Solder Paste Inspection

Solder paste printing is the first stop for circuit board assembly, and inspecting the solder paste print before the assembly is soldered in the reflow oven is an excellent time for easy preventative fixes. Given that studies show that as much as 70% of all defects on PCBAs come from improper solder paste printing, solder paste inspection (SPI) is an essential step in PCBA production.

Inspection and evaluation of solder paste printed boards can be done using 2D or 3D X-ray imaging. Both will evaluate solder paste coverage, but with the use of a laser, 3D testing will also provide coverage and paste volume data. Since solder paste volume has been linked to long-term joint reliability, 3D imaging is often the preferred quality control method.

Properly implemented, and with the aid of experienced SMT engineers monitoring the process, SPI will improve yields and save money by identifying and correcting solder paste errors early.

SPI is useful in both the development (prototyping) and in-process stages of production. In addition to spotting solder print defects (insufficient paste, bridging, etc.), solder paste inspection will gather information on printing consistency and volume, providing valuable statistical analysis that can guide design improvements.

A solder paste printing machine deposits solder on a printed circuit board
Given that studies show that as much as 70% of all defects on PCBAs come from improper solder paste printing, SPI is an essential step in PCBA production.

Automated Optical Inspection

Optical inspections are a critical form of testing. Even traditional optical inspections, whether done by the naked eye or with the aid of magnifying glasses and microscopes, yield valuable information—especially when performed by experienced engineers and technicians. But today’s PCBAs, with their highly complex grid arrays and micro-sized components, also benefit greatly from the accurate and efficient capabilities offered by automated optical inspection (AOI).

With a camera system capable of capturing 2D or 3D images, AOI machines scan a PCBA and compare the images to parameters and reference images in the design database. This allows the system to detect missing components, incorrect components, skew or misalignment, and other visually identifiable defects. Any defects that are discovered can then be flagged and pulled for further inspection or rework.

Although 2D camera and sensor quality are equal to that of 3D imaging on AOI machines, 2D imaging is limited to evaluating visible components. With 3D X-ray, defects in hidden areas of integrated circuits can be identified. 3D X-ray can take longer and may come with an added cost, but with component interconnects becoming smaller and boards more compact, it’s often the best choice for especially complex PCBAs and devices.

AOI systems are highly versatile, and so are typically used at more than one stage of the manufacturing production line. Their use pre- and post-reflow is common, depending on the board and the types of defects that must be avoided. Your EMS provider will help you decide where AOI fits into your device manufacturing process by considering your production volume and rate, as well as the defects that are essential to avoid.

Flying Probe Test

While vital inspections such as SPI and AOI check defects on a board’s surface, component placement, and stability, a flying probe test (FPT) assesses and verifies the functionality of individual components on the PCBA. Discovering flawed components means they can be pulled and replaced before creating device failures.

To do this, probes “fly” over the soldered board on high-speed gantry mechanisms, and conduct a programmed test sequence set up by SMT engineers in accordance with the specific requirements of the device under test (DUT). Without powering up the board, the FPT conducts its test with as many as 20 moving probes that check individual components. The probes test parameters such as voltage measurements, shorts, opens, bad contacts, and diode issues.

Because the FPT is considered “fixtureless,” it does not come with high tooling expenses—a cost-saving benefit that can make it an ideal choice for prototypes and small to medium production volumes. 

In-Circuit Test

While FPT is useful for small volumes, the in-circuit test (ICT) fixture—which uses the same methodology (testing individual components) as the FPT—can be a good choice when it comes to products that are fully developed and in production at high volume, due to its very short test time compared to FPT.

As test fixtures, ICTs require DFT-savvy engineers to incorporate the test points in the board and use custom tooling to build the fixture. Creating the fixture naturally comes with upfront tooling costs, which can make it prohibitively expensive for prototyping, but for higher volume runs this cost is offset by the lowered expense of streamlined production. An ICT fixture can lower the per-unit cost significantly—by as much as ten or more units for every one unit that the FPT processes.

Functional Circuit Test

As the final step of electronics testing, the functional circuit test (FCT) fixture does just what it says on the box: test the device’s functionality. This test provides a pass/fail determination of the DUT’s functionality, validating the device’s design and implementation. The test is conducted by simulating the operating environment that the product will be used in, ensuring the board functions as intended, and is free of errors.

In addition to design flaws, FCT can spot both manufacturing defects and software bugs that might affect the device’s performance. It can also show whether the device adheres to all relevant standards and specifications. For critical devices, such as medical equipment or automotive systems, functional testing is crucial for ensuring safety and reliability, and so a series of FCTs may be necessary. This is where thorough testing helps verify that the device operates correctly, reducing the risk of malfunctions or complete failure.

Three trays of assembled printed circuit boards
Functional circuit testing lets you check how a PCBA will perform under real-world conditions.

Driving Innovation and Building Trust

Whether they’re in consumer devices designed to entertain, or medical devices created to save lives, complex PCB assemblies with small components demand rigorous testing and inspection. Comprehensive testing ensures that electronic devices meet design specifications, adhere to industry standards, and deliver optimal performance. 

It’s also true that the process of electronics testing not only ensures quality, it also drives innovation. By providing comprehensive, detailed feedback, testing enables iterative improvements that lead to cutting-edge advancements and enhanced user experiences.

That’s why it’s more important than ever for manufacturers to embrace robust testing practices. Ensuring high performance and reliability enables electronics companies to establish trust with customers, maintain a competitive edge in the market, and build a reputation for excellence.

A Contract Electronics Manufacturer You Can Rely On

Want to ensure that your product offers a superior customer experience? We use a broad range of testing technologies and protocols—including AOI, FPT, and both 2D and 3D X-ray imaging—to ensure that your products make it out the door without defects. Contact us today to learn more.
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Imagine you’ve designed a breakthrough electronics device, a product that’s sure to put your company on the map. And after hundreds of hours of brainstorming, designing, and review, you’re ready to make your device a reality and enter production. But just days later, production stops before it’s even started. It turns out the nonstandard component you included in your design will have to be soldered by hand—dramatically increasing the cost of production. So now it’s back to the drawing board—costing you a significant delay, and giving your competitors a chance to catch up. How did this happen? And how do you keep it from happening again? The answer is Design for Excellence.

What is Design for Excellence?

Design for Excellence (DFX) has a dual meaning. The first interpretation is straightforward: the “X” in “DFX” stands simply for “eXcellence.”

Additionally, however, Design for Excellence (DFX) is an umbrella term, where the “X” stands for any number of protocols for developing a better product at the concept design phase. These protocols include Design for Sustainability (DFS), Design for Manufacturability (DFM), Design for Test (DFT), and a host of other manufacturing principles.

DFX provides a systematic, holistic approach to design that focuses on all aspects of development throughout the product’s lifecycle. With traditional engineering design processes, problems are usually identified and fixed after the design phase. Design for Excellence, however, shifts the emphasis on solving these problems to the early design stage—saving companies both money and time. And whereas traditional engineering teams tend to work in silos, a DFX approach relies on greater collaboration early in the design process, making it easier to spot potential roadblocks and craft solutions.

Eight Important “X’s” of the DFX Methodology

A DFX approach relies on greater collaboration early in the design process, making it easier to spot potential roadblocks and craft solutions.

A 3D printing machine in action, making an electronics component or shell.
Longtime DFX disciplines like DFM and DFT have been joined by newer protocols like Design for Additive Manufacturing (DFAM).

DFX used to refer to two or three types of design protocols, like Design for Manufacturability and Design for Test. But new priorities, and emerging technologies, have ushered in a host of new DFX sub-disciplines, and that number continues to grow. Below are eight types of DFX methodology that are making a mark in electronics manufacturing:

Design for Manufacturability (DFM): A Design for Manufacturability (DFM) analysis looks at your electronics design from the eye of the manufacturer. Ideally, this analysis occurs early in the design process, as there is an inverse relationship between cost and benefit during a product’s journey from design to release. A comprehensive analysis looks for ways to design the components of an electronic product in such a way that it will be easy to manufacture—optimally producing a better product at a lower cost. For example, a good analysis will catch any design flaws that might impact a circuit board’s functionality.

Depending on the products you make, some DFX sub-disciplines will matter more than others.

Design for Additive Manufacturing (DFAM): Design for Additive Manufacturing is DFM specifically applied to additive manufacturing (also known as 3D printing). In DFAM, the goal is to optimize the design of a product to take advantage of the benefits of the additive manufacturing process. And these benefits are significant. With 3D printing: 1) increased complexity does not equal increased cost; 2) total production costs are not significantly altered for larger volumes; and 3) integration with other digital design tools, such as computer-aided design (CAD), is considerably streamlined. Because additive manufacturing is constantly evolving, the best practices of DFAM are likewise rapidly advancing. So to get the most from DFAM, be sure to work with a team that’s up to date on new developments in this field.

Design for Sustainability (DFS): Design for Sustainability (DFS) is a design approach that considers the environmental and social impacts of a product throughout its lifecycle. There are many ways a designer can reduce a product’s overall environmental impact. Using more sustainable materials in the production of electronic components, for example, leaves less chemicals, plastics, and metals in the local landfill. Designing energy-efficient products that use low-power processors and LED displays is yet another way a designer can satisfy the demands of today’s environmentally conscious consumers.

Design for Test (DFT): Thoroughly testing products before they reach the market is crucial for avoiding returns or, even worse, expensive recalls—which is why DFT is so important. DFT in electronics is all about making it easier to test your devices during the critical debugging and manufacturing stages. A good PCB assembly design not only makes testing easier but also enables more accurate and reliable readings during testing. Fortunately, advances in rapid prototyping have greatly improved the DFT process. With rapid prototyping, prohibitive barriers of cost and time are removed. Rapid prototyping also accommodates the separate testing of components—a useful diagnostic practice that has only recently become reasonably easy to do.

Design for Assembly (DFA): In essence, Design for Assembly is about simplifying a product so that its cost of production is reduced. Engineers analyze the design of both the individual parts and the whole product in order to identify ways to optimize the assembly process, thereby reducing both production and total product lifecycle costs. Although DFA is a relatively new addition to the DFX landscape, companies have been applying DFA protocols in various ways for decades. For example, General Electric published an internal handbook as early as the 1960s which included many of the principles of DFA as we know and understand them today.

Design for Reliability (DFR): Design for Reliability focuses on ensuring that a particular product or component, such as an electronics chip, serves its intended function within a given environment throughout its lifecycle. Similar to the other DFX protocols, DFR happens at the design stage—long before actual physical prototyping begins. For example, engineers can use DFR principles to produce chip designs that anticipate and respond to the reliability issues that stem from circuit aging. While it can be tempting to cut corners—70 percent of a project’s budget can be attributed to design—a proper design producing a reliable product saves money in the long run. A savvy engineer knows that it’s cheaper to design for reliability than to test for reliability.

Design for Cost (DFC): Design for Cost is a protocol which analyzes and evaluates a product’s lifecycle cost and then modifies the design to reduce that cost. Design for Cost aims to increase system performance while simultaneously delivering value. One way to achieve a positive outcome in DFC is to emphasize simplicity, as complexity often leads to increased cost. As Albert Einstein once said, “The best design is the simplest one that works.”

Design to Cost (DTC): Design for Cost should not be confused with Design to Cost. The goal of Design for Cost is to increase system performance while reducing cost, whereas Design to Cost involves the iterative redesign of a project until it falls within budget. In the Design to Cost scenario, a company may accept reduced performance in favor of reaching its budget goals.

Making the Most of Design for Excellence

DFX encompasses just about every aspect of your product’s design. But depending on your product and your priorities, some DFX sub-disciplines may matter more than others. For example, if you make Class II medical devices, then DFT and DFR may be top of mind for you. Makers of consumer electronics might want to focus more on DFC and DFA—and more and more, DFS as well. To make sure that your product goals are met, it’s important that you work with a contract manufacturing team that’s familiar with a wide range of DFX sub-specialties, so you can focus on the design aspects that matter most to you, whether that’s cost, sustainability, time to market, or another goal.

A DFX Partner You Can Rely On

Are you ready to partner with a contract manufacturer that can help you design for excellence? Our engineers are experts in DFM, DFT, DFS, and other DFX protocols. We can help you maximize your product’s potential and streamline your production. Contact us today to learn more.
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by Andrew Williams

The manufacturing labor shortage is a pressing concern for American electronics companies, where the scarcity of long lead-time components is matched by a shortage of skilled workers. Decades of job losses in the manufacturing sector have resulted in a lack of interest in manufacturing careers among potential workers who lack personal connections to the industry. To address this issue, companies are exploring various strategies, such as increased automation and training collaborations with community colleges. They have also found success by offering flexible work schedules that cater to the preferences of college students, single parents, and retirees.

One effective solution for electronics companies seeking to combat labor shortages is to consider populations that have been overlooked in the past, such as people with disabilities. PRIDE Industries, the company where I work as Director of Product Engagement, has been a pioneer in employing individuals with disabilities since its inception in 1966, when it was founded by a group of parents seeking employment for their adult children with disabilities. Today, PRIDE Industries is the leading employer of people with disabilities in the nation. We employ thousands of individuals in our lines of business and have helped thousands more find jobs with other companies.

How Employees with Disabilities Mitigate the Manufacturing Labor Shortage

The line of business in which I work—Manufacturing and Logistics Services (MLS)—was established in the 1990s when one of our customers asked us to manufacture a new product for them. Since this product had a simple production flow, it was well-suited to inexperienced production workers. Starting with a job shop that performed through-hole assembly using a slide line, our division has grown into a comprehensive EMS provider with full SMT capabilities. We now produce a variety of products, including Class II medical devices, using an inclusive workforce that includes a high number of people with disabilities.

It’s a proven fact that employees with disabilities have lower turnover and absenteeism than average.

Head shot of Andy Williams
Andrew Williams, Director of Product Engagement, PRIDE Industries

People with disabilities are one of the most underrepresented groups in the labor force. Two-thirds of working-age Americans with a disability are unemployed, even though many want to work. Given that one in four Americans has a disability, this is a significant waste of talent.  At PRIDE Industries, we’ve successfully created employment opportunities for this labor pool, which enables us to reap the benefits of a broad talent base.

How to Make the Factory Floor More Inclusive

Integrating people with disabilities into the production line requires thoughtful planning. For example, job descriptions sometimes need to be modified to align better with an employee’s specific skill set. And often, new fixtures, tooling, and jigs must be developed to support the integration of employees with disabilities into production roles. But the benefits of these efforts are substantial. Our inclusive workforce demonstrates a level of focus and consistency that surpasses that of the general workforce. And it’s a proven fact that employees with disabilities have lower turnover and absenteeism than average. It’s no surprise, then, that our 30 years of experience have taught us that the benefits of accommodating employees with disabilities more than outweigh the costs.

While hiring people with disabilities may not completely resolve the manufacturing labor shortage faced by electronics manufacturers, it can significantly alleviate talent issues for many organizations. And there are broader societal benefits to recruiting from this underrepresented segment of the labor market. By providing the right opportunities, we can empower individuals with disabilities to become independent. Hiring from this talent pool also addresses chronic unemployment and reduces the underutilization of valuable production resources, a benefit that aligns with lean manufacturing principles.

For over 30 years, PRIDE Industries has proven the value of an inclusive workforce. Employing people with disabilities not only changes lives, but also brings real material advantages to the companies that provide these opportunities—advantages that extend far beyond the obvious ESG benefits. Even the surrounding community benefits, in the form of reduced safety net costs and an increased tax base. When you build an inclusive workforce, it’s a win for your employees, your company, and the community you call home.

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Looking for a skilled team to produce your next electronics device? Our highly trained, inclusive manufacturing workforce ensures top-notch quality. And our team of SMTA-certified process engineers can help you design, test, and get your product to market fast. Contact us today to learn more.
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Have you ever heard the story behind the household cleaner Formula 409®? It’s a tribute to the tenacity of two Detroit-based scientists. It took them 409 attempts until they hit upon a cleaning formula that worked the way they wanted.
The journey of Formula 409®’s inventors is not an anomaly. It took Sir Tom Dyson, inventor of the dual cyclone bagless vacuum cleaner, exactly 5,126 iterations to achieve his desired result. And although the number of iterations a new product goes through can vary significantly—due to design team expertise, the complexity of the product, the industry, etc.—almost all products go through a trial-and-error phase before success is achieved. And all this experimentation can be costly. Fortunately, inventors have an ace up their sleeve: prototyping, and more recently, rapid prototyping.

The efficiencies of rapid prototyping support iterative design and therefore more highly refined components.

What is a Prototype?

A prototype is a draft version of a product or design which allows the creator to test and improve a concept or process before releasing a final version. For example, an inventor might share a prototype with a manufacturer for help in modifying and testing the design. In electronics, one might build an actual version of a theoretical circuit to verify that it works. And if it doesn’t—which at the beginning of the design process, is often the case—the prototype provides a physical platform for debugging.

What is Rapid Prototyping?

Creating a prototype saves time and money; however, traditional prototyping can still be costly and time consuming. Fortunately, manufacturers now have rapid prototyping. As its name implies, rapid prototyping is a way to quickly fabricate a prototype to aid designers in visualizing, redesigning, and developing a product before mass production. Rapid prototyping differs from traditional prototyping in that it emphasizes speed, efficiency, and flexibility.

Rapid prototyping is made possible by new advances in technology, such as the FlexBoard, which was developed by MIT researchers. The FlexBoard is a flexible breadboard that allows rapid prototyping of objects with interactive sensors, actuators, and displays on curved and formable surfaces. Because of the FlexBoard’s design, it allows for more rapidly customizable interfaces.

A man and a woman, standing at a desk in a manufacturing facility, looking at a laptop computer screen.
With rapid prototyping, designers and engineers can immediately update designs based on real-world testing.

Other advanced prototyping technologies include computer-aided design (CAD) and additive manufacturing, more commonly known as 3D printing. Almost all rapid prototyping involves CAD, a technology that relies on a computer to help in the creation, modification, analysis, and optimization of a design. CAD allows for the design and production processes to blend seamlessly, since an electronic output file from the software leads directly to the part production, with changes able to be made at any time during the workflow. 

The auto industry was among the first to embrace rapid prototyping, but other industries were not far behind. Today, electronics manufacturers are creating rapid prototype circuit boards for a wide variety of applications, particularly for products that have no leeway for error—such as defense, medical, aerospace, and robotics devices.

Why is Rapid Prototyping So Important?

The time and effort needed to get a sophisticated electronics product to market is legendary, and the growing complexity of these devices isn’t making it any easier. But a concurrent development is. CAD was one of the first rapid prototyping technologies developed, and it has sped up the development process for new products considerably. Now the addition of a newer technology, 3D printing, is cranking up the speed even more.

And that’s a good thing, because semiconductors—and the devices they enable—are evolving more quickly than ever. Customers now expect significant improvements to existing products on a regular basis. And new products have to dazzle. Rapid prototyping is what makes that possible, by optimizing development and production in seven important ways:

3D printing allows designers to create non-planar electronics with unique form factors.
  • Efficiency: Rapid prototyping techniques provide more efficiency during the R&D process. With traditional prototyping, engineers frequently wait weeks to receive a prototype from a short-run manufacturer—only to discover the need to start again. With rapid prototyping, designers and engineers are now able to produce prototypes in a matter of hours so they can immediately update designs based on test results.
  • Cost-effectiveness: The increased efficiency of rapid prototyping also saves money. With rapid prototyping, companies can test boards and find problems before a production run—saving both material and employee time. Furthermore, rapid prototyping accelerates the testing and verification process, reducing the overall manufacturing and design costs for a project.
  • Better Components: Iterative design is a cyclical methodology for prototyping, testing, analyzing, and refining. This methodology enables manufacturers to produce the best electronic components possible. In the past, it was not always possible to produce an accurate prototype board that allowed designers to determine how best to modify a board layout for optimal performance. The efficiencies of rapid prototyping, however, support iterative design and therefore more highly refined components.
  • Fewer Supply Chain Challenges: Supply chain challenges have affected many industries, including electronics. You can’t create a prototype if you don’t have the materials. Fortunately, additive manufacturing technology provides a simple solution: create it yourself on a 3D printer.
  • Flexibility in Materials: Additive manufacturing systems are more flexible with regards to materials than tools typically used in traditional prototyping. The 3D printers used with rapid prototyping can accommodate a wide variety of materials, such as plastic, powders, resins, metal, and carbon fiber.
  • Flexibility in Design: Designers are no longer limited to creating rigid planar PCBs. Because of its layering properties, 3D printing allows designers to create non-planar electronics with unique form factors, as well as integrate functionality on to a single board. Rapid prototyping also allows testing of complex designs that would otherwise be costly and time-intensive to produce. For example, with a perfboard or a stripboard there are soldering limitations and track destruction challenges that don’t exist with rapid prototyping.
  • Small Batch Runs: With traditional prototyping, it’s often not practical to produce a small batch of PCBs. With rapid prototyping, on the other hand, it’s feasible to produce limited batches of 5 to 100 units.

The Future of Rapid Prototyping for Electronics

Innovative new technologies, such as advancements in CAD and other design tools, will continue to increase the use of rapid prototyping. And as more robust systems and materials for additive manufacturing become available—and more affordable—rapid prototyping of electronics will become more widely adopted and better integrated with traditional manufacturing and assembly steps.

These developments are already well under way. Artificial intelligence (AI), for example, is expanding into multiple disciplines, and the area of rapid prototyping is no exception. As AI improves, it will continue to be integrated into rapid prototype development, with the ultimate goal of more data-driven decisions and seamless testing.

How far can this trend go?

Despite all the advances in CAD, additive manufacturing, and AI, full automation of electronics manufacturing remains a distant goal, according to All About Circuits, one of the world’s largest, independent online communities for electrical engineers. That said, it is certain that strategies like rapid prototyping will continue to move the industry forward and remove previous barriers. As with most developments in electronics manufacturing, the limits of rapid prototyping technologies have yet to be reached.

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