The PCBs you might be designing in the future

The purpose of the Printed Circuit Board (PCB) is to connect your electronic components. That will never change, but it’s capacities will. The flexibility of the boards means that even the simplest, smallest change to new technologies is turning the industry on its head. Such alterations also reflect how the boards will be constructed in years to come.

What are these trends and technologies to shape the sector – and, as a result, what will impact the projects of a new generation of engineers?

Thanks to sleek design software and efficient manufacturing processes, PCBs can be produced at a much higher rate than they once were. Available to designers throughout the world, the multi-layered, cleverly-constructed systems are more readily available today. But, owing to the fast-paced world of technological developments, PCBs must evolve too.

Experiencing swift growth within the PCB industry are flexible PCBs. They’re gathering speed so much, in fact, that by 2022, Allied Market Research reports that they’re expected to reach $27 billion. They’re highly sought-after due to the fact that they can withstand more bending and stress than their rigid counterparts. On top of this, they’re thinner and lighter, but still remain quite easy to manufacture in large volumes.

Since consumers want faster, slimmer and more streamlined devices, it’s no surprise that industries are looking for high-performing PCBs that develop as their businesses do.

PCBs may well be improving, but there’s always room for more change – from the shape of the boards to the accessories that accompany them. But with new designs and capabilities, comes new challenges in the workplace, which means the predictions for future PCBs include a host of key factors.

PCBs and wearable technology

One of these considerations is wearable technology’s affiliation with PCBs. Wearables may be modest in size but they’re ‘packed full of functionality’. For design engineers, this can mean an issue or two may arise.

Multi-layer boards are ‘tightly packed to fit within beautifully designed product casing’; in order to keep evolving, they need to retain their functionality while losing thickness – something they don’t currently offer.

Board cameras and PCBs

Mounted onto a circuit board, board cameras – also known as PCB cameras – are made up of an image sensor, a lens and an aperture. Taking digital images and videos, the cameras are extremely compact and are utilised across a host of industries. Some of these applications include medical instruments – pill-sized cameras can now be swallowed by patients to allow for video footage to be taken of the digestive tract – consumer electronics or even surveillance technology. The latter sees PCB cameras utilised and concealed in small objects, making them ideal for organisations to keep a close eye on their staff or the public.

Ensuring they can be slipped inside any electronic device, from a tablet to a cell phone, the technology behind the cameras is expected to develop further still in the next half a decade or so.

Miniaturization and high-density interconnect

Consider the size of your first cell phone; we’re betting it was quite a lot bigger than the one you have now.

With smaller electronic devices being the Holy Grail for tech fans, PCBS need to become much smarter and much more efficient. High-density interconnect technology is key, with developments in HDI technology, meaning PCBs may become even smarter.

A greener approach to manufacturing

Greener manufacturing is on everyone’s agenda, with plenty of customers boosting their operations, saving money and doing their bit for the environment.

If PCB technology is to stay ahead of the curve it, too, should consider its wider environmental impact. The emergence of lead-free solder came under fire recently, since it requires manufacturing processes which expend far more labour than is manageable long-term.

Thankfully, a solution is therefore on the cards, owing to a worldwide shortage of fuel and energy sources and a resulting demand for environmentally friendly manufacturing. Originally created using fibreglass as a substrate, which in itself does not cause too much strain on the environment, new advancements could mean fibreglass gives rise to materials like liquid crystal polymer, which provides a a high rate of data transfer.

Cloud-based health care and technology

Helping healthcare providers securely store patient records in the cloud, advancements in technology mean consumers can access vital details via their smartphones. While this represents a leap for the healthcare industry on the whole, it does highlight the fact that PCB technology needs to do a lot to keep up.

The pill-sized cameras are just one of these advancements – and in order to evolve, PCBS, like smartphones, tablets and other electronic devices, need to become smaller as time goes on.

Also used by drivers, in the form of dashboard (aka ‘dashcams’), the capabilities in technology are being explored further by those who make PCBs. One example is mobile phone accessory brands, who are increasingly looking at ways to make more compact versions of the devices they sell.

3D printing

Revolutionising future designs in electrical systems, 3D printing is responsible for a host of advancements – firearms and ammo in 3D form being just two.

Creating 3D circuits by printing a substrate item layer by layer, before adding a liquid ink on top featuring electronic capabilities, 3D printing looks set to evolve even further. For instance, the addition of surface-mounted technology can result in a circuit which can take the form of any shape.

While 3D printing may be moving towards high-volume production, it can still be environmentally-friendly. Low cost, recyclable materials can be used. The industry continues to evolve, as manufacturing businesses hit upon new ways to use the technology behind 3D printing.

One such example is the kinds of materials which can be used to manufacture circuits. Flexible and biodegradable substrate materials are increasingly becoming viable options, with designers ensuring the industry keeps evolving, thanks to new and innovative ideas.

High-speed functionality

Since we live in a fast-paced world, technology is moving at breakneck speed in order to keep up with consumers’ demands. It is not enough to simply own the latest tech; we want it quicker than anyone else too.

PCB technology is one sector which needs to adapt, in order for our devices to keep up with advancements in technology. A high-speed PCB tends to be one in which the signal’s integrity is affected by the layout of the circuit. Everything from the dielectric of the PCB to the proximity to other signals can affect the signal’s integrity – and new methods are, of course, underway to combat this.

Which industries are getting behind the trend for flexible PCBs?

PCBs, in general, are having to become much smarter – and it’s because they’re used in such a wide range of products. But what about businesses; how are they utilising PCBs, particularly the trend for flexible PCBs?

Flexible displays are just one area of interest. While these have been in existence for some time, they’re quite difficult to track down. This is due primarily to the high manufacturing costs associated with them. Once these manufacturing costs decline, though, flexible devices are set to be the next buzzword in portable technology. The reason for that is simple: they can handle more stress than rigid systems. Of course, the need for bendable PCBs will soon become apparent.

Elsewhere, in the LED lighting industry, flexible PCBs may soon be a key requirement. Since LED lighting is an environmentally-friendly alternative to traditional bulbs, flexibility is vital. Enter flexible PCBs, which will allow the consumer to bend strip lighting to complement their room – or home’s – interior.

Routine health checks are easier

Looking at the medical industry again, flexible PCBs will be utilised, too. While miniaturization and flexibility is vital in the sector, flexible PCBs will enable medical professionals to perform routine health checks far more easily.

Thanks to flexible PCBs, for instance, medical device designers will be able to create implements that make diagnosing health issues simpler. Selected for their reliability, this type of PCB is used widely in medical devices.

In terms of the sheer volume of electronic waste, PCBs have long been a huge culprit. Computers, smartphones, TVs and laptops are just some gadgets which may contain parts that aren’t environmentally-friendly and/or biodegradable.

Up, up and away

In the aerospace industry, the future is also looking particularly exciting. The demand for specially-designed PCBs is set to be huge, says Business Matters:

“Actually, even today, a number of PCB designers are employed at SpaceX, where their role is incredibly important. The same is the case with NASA and space agencies from other parts of the world, most notably Roscosmos and CNSA.”

With PCB design becoming easier, the software is also becoming better, with plenty of tools making designers’ lives much smoother. Autodesk and Altium – two key software companies – are working to develop programs that will make the design of printed circuit boards simpler, which means, in the future, training to become a good PCB designer will be easier too.

Environmentally-sound options

Presenting a big issue, ‘e-waste’, as it’s known, is a problem for consumers as well as businesses. Since some PCB materials don't degrade very well, the challenge is on for engineers and manufacturers to come up with ways they can be disposed of properly. A change in production processes may mean, therefore, that engineers swap traditional substrates with options which are more environmentally sound.

Presently utilised as connecting components in electronics, PCBs’ applications extend far beyond those most of us are aware of. It’s a fact that has prompted engineers to work on making the PCBs the active systems. By doing this, the number of components required in the PCB would be reduced, while functionality would not be affected.

The future’s innovative

As consumers’ needs alter, so will PCB technology, with new and innovative ideas continually coming to the fore.

Engineers are encouraged to keep an eye out for new materials and changing trends, each one influencing the way you work and ensuring your projects perform more effectively, while also remaining cost-effective and being more environmentally friendly.

The future’s certainly bright in the PCB sector – and engineers are encouraged to watch this space.

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