US electronics corporation building systems for harsh environments
A multinational US-based corporation with operations across Europe, developing advanced electronic systems for demanding industrial environments. It operates in contexts where reliability, durability, and compliance with strict engineering standards are critical to system performance.
PCBs for long lifespans under IPC Class 3 requirements
The project involved developing PCB solutions for systems expected to operate in harsh environments for extended periods of time.
While initial requirements appeared straightforward, further analysis revealed significant complexity driven by:
- long operational lifespans
- exposure to demanding environmental conditions
- strict manufacturing and quality standards (including IPC Class 3)
- non-standard design parameters such as stack-up, thickness, and surface finishes
At the same time, limited availability of qualified subcontractors made manufacturing more challenging, especially for small production batches.
Given that PCBs form the backbone of the entire electronic system, any design or manufacturing issue could directly impact system reliability.
Requirements for signal integrity and long-term PCB reliability
To meet these requirements, the PCB design needed to:
- ensure long-term reliability under demanding environmental conditions
- meet strict manufacturing and quality standards
- support high-performance electronic systems
- address space constraints and system complexity
- minimize electrical noise and ensure signal integrity
The goal was to create a design that could perform consistently over time while remaining manufacturable under strict constraints.
High-reliability PCB design with industrial-grade materials
A custom hardware design approach was implemented to develop high-reliability PCBs, with a focus on precision, material quality, and validation throughout the development process.
The design process carefully addressed layout, trace routing, and component placement to optimize both performance and manufacturability.
Material selection played a critical role, with industrial-grade components chosen to ensure durability, thermal stability, and mechanical strength.
Testing and validation processes were applied to confirm that designs met performance and reliability requirements before production.
Close collaboration between engineering, design, and manufacturing teams ensured that technical decisions aligned with both system requirements and production capabilities.
The project highlights how PCB layout, material selection, and manufacturing constraints shape the reliability of electronic products. Our guide to the hardware design process explains these considerations in more detail, including their role in developing production-ready hardware.
The design and validation process was supported by industry-standard engineering tools:
- Altium Designer for PCB design and layout
- LTspice for circuit simulation and validation
How layout and routing protect signal integrity
The PCB serves as the foundation of the electronic system, connecting components in a structured and reliable way.
Optimized layouts and routing improve signal integrity and reduce interference, supporting stable system operation.
Carefully selected materials and manufacturing parameters ensure that the boards can withstand environmental stress over long periods.
Validation processes confirm that each design meets required standards before deployment.
Lower failure risk in demanding environments
The implementation improved the reliability and performance of electronic systems operating in demanding environments. By addressing design and manufacturing challenges early, the risk of failures was reduced and system stability increased. Improved collaboration between teams also enabled more efficient development and problem-solving.
Results: manufacturable high-reliability PCBs for long-term operation
The approach delivered improvements across key areas:
- High-reliability PCB performance, supporting long-term operation
- Reduced risk of system failure, in critical environments
- Improved manufacturability, despite strict constraints
- Enhanced system performance, through optimized design
- Greater design flexibility, supporting complex electronic systems
Frequently asked questions
What does IPC Class 3 mean for a PCB designed for long service in harsh environments?
IPC Class 3 is the high-reliability manufacturing and quality class, so it tightens what fabrication and assembly must achieve. In this project, InTechHouse designed PCBs for systems expected to operate in harsh environments for extended periods, where IPC Class 3 combined with non-standard stack-up, thickness and surface finishes made manufacturing harder, especially for small production batches.
How do PCB layout and routing protect signal integrity in high-reliability industrial electronics?
Optimized layout, trace routing and component placement reduce electrical noise and interference, which supports stable system operation. In this project, InTechHouse addressed layout, routing and placement to balance performance with manufacturability, and testing and validation processes confirmed that each design met performance and reliability requirements before production.
How can PCB designers reduce manufacturing risk when few qualified subcontractors can build small batches?
Close collaboration between engineering, design and manufacturing teams keeps technical decisions aligned with what production can deliver. In this project, InTechHouse worked this way because limited availability of qualified subcontractors made small production batches difficult, and addressing design and manufacturing challenges early improved manufacturability despite strict constraints.
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