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IoT PCB considerations for Startups

As IoT devices are so cutting edge, you would believe that getting an IoT printed circuit board (PCB) project off the ground starts by reinventing the wheel and facing a good deal of technical complications. This is not true.
Nevertheless it doesn’t imply IoT startups have a certain way to stardom. Facing them is quite a few design and manufacturing factors to consider which are unique to these small products. These considerations are required to be considered for the fresh new IoT device to reach their goals.

On the plus side, it’s essential for IoT startups to recognise that the basic foundation for a successful cool product exists. This indicates experience and knowledge regarding the design, fabrication and assembly of such innovative products are existing. Also, the best advice is for heady IoT product enterprisers and innovators to look closely at the counsel that experienced electronics manufacturing services or EMS vendors have to give you. These businesses along with their engineering team members have previously implemented the task with revolutionary IoT businesses in Silicon Valley joining the beginning of this surfacing market.

The PCB of an IoT device is a different beast than the traditional one, which is considerably larger and flat. IoT units, on the flip side, comprise mainly of either rigid-flex or flex circuit assemblies, which come with their own groups of design layout, fabrication and assembly considerations and nuances.


A key concern is to seek out veteran designers who have accomplished many rigid-flex PCB designs. PCB space for an IoT device is confined. So you want the designer to have directly layout experience to correctly design crucial parts on that little space.

Additionally, nearly all IoT gadgets aren’t stationary; they get significant movement and folding. Right here, the veteran designer plays an important role in determining bend ratios and lifecycle iterations as a critical part of a design. Additional crucial design layout considerations incorporate signal trace thickness, number of rigid and flex circuit layers, copper weight and stiffener placement. Stiffeners are used on flex circuits to make certain parts attached with the flex circuit remain tightly in place to avoid movement.

Yet another aspect to consider is through-hole element placement in rigid-flex circuits. Why is that pretty important? Most IoT products are based on surface mount device placement. Nevertheless , there might be through-hole parts, which are commonly attached to either the rigid part or the flex part of the board. Through-hole parts are generally employed to communicate input/output or I/O signals to the outer world. Doing this, those signals can show up utilising an LCD or LED monitor. Through-hole element placement is a critical account in an IoT system as when applied on the flex area of the board, suitable stiffeners must be designed and employed for excellent assembly.

Lastly in the layout category, the heat that parts deliver ought to be deemed. IoT gadgets are ever more challenging with rigid-flex and flex circuits featuring over 12 – 14 layers. A few gadgets are digital. Nevertheless , increasingly more analog products are getting used in IoT products. Analog circuitry generates considerably more heat than digital ones. It implies heat expansion and then contraction rate are required to be thought about. In tech lingo, this is actually referred to as the Coefficient of Thermal Expansion or CTE and the right control over it.


Choosing the proper fabricator is very important and is linked to the EMS corporation you’ve picked. The fabricator you want should have IoT PCB fabrication practical experience. Amongst crucial considerations here are insuring strong adhesions between layers on both rigid and flex circuit sides, realizing all the crucial calculations and obtaining a strong comprehension of when current moves from the rigid side to the flex side.

Such fabricators also need to get an in-depth knowledge of very miniature parts similar to 0201 and 00105 device packages, package-on-package, and the use of fine-pitch ball-grid array or BGA packaged devices.

Additionally they must have experience of designing boards with extremely tight tolerances in terms of footprint for those sorts of BGA devices, in terms of up-to-date capabilities like laser direct imaging for putting the solder mask on the board. They ought to have laser drills for via drilling with sizes of 5 mils or under as these IoT products could be so compact that a standard drill size of 5 to 8 mils probably won’t be enough. They could require to go to a 3 mil, which means you must have an cutting-edge laser drilling capability on-site.

If you’re placing via-in-pad, it’s a great way to make use of the small land which is available on the rigid-flex board, however , it presents trouble for assembly. If vias aren’t entirely planar or flat in shape, it could be tricky throughout the assembly of those tiny BGA packaged devices. That is because non-planar surfaces might put in danger the integrity of solder joints.

At times via in pads leave bumps in the event they’re not scrubbed appropriately after positioning the vias and gold finish on the top. When there are bumps, then the solder joints in the assembly for those tiny BGA balls in those IoT devices would not be an ideal joint. It may create irregular connections, which might be a larger issue to handle and repair. It all boils down to which EMS corporation you’re working with because they’re the ones who will pick the fabrication house to make a successful IoT device for you.

PCB Assembly

It’s very important to take a look at veteran EMS companies that have efficiently assembled IoT and wearable PCBs because they have unique tooling and fixtures already existing, which are important for assembly to make sure components are placed the proper way, accurately and the printing is made in the right way.

Printing generally is a problem for IoT products. If it’s a rigid-flex board, then you will find there’s a change between thicknesses of the rigid and flex circuit portions, that means a special fixture is required to retain the complete rigid-flex board planar or absolutely flat to get effective printing to become executed.

Startups ought to be geared up to choose the proper manufacturing partners and EMS companies. This way they can make sure they have adequate experience beforehand to get the multitude of design, fabrication and assembly details successfully performed since they are crucial to a triumphant and timely IoT product release.