Using Embedded Resistors and Specialized High-Speed PCB Materials
Challenge
Epec was approached by an existing customer that we were currently manufacturing printed circuit boards for after we sent out an email blast outlining our embedded resistor capabilities.
Embedded resistors are a technology that has been around for the past 20 years, however, they’re not cheap. Customers have not needed this technology in the past or have found other ways like blind and buried vias and other challenges that are running out of space for components. This customer had used another PCB supplier, had used embedded resistors before with them, but had numerous quality and delivery issues. They didn't have the ability to build them in-house and were looking for another supplier that has experience with this technology.
With their current PCB supplier having delivery and quality issues, and previously having credibility with Epec, from the previous parts we had already built for them, they came to us to see if our solutions could help solve their current problem.
Solution
After engaging with our sales team, product managers, and engineers on a Zoom call, they outlined to us what the requirements were based on the material and the issues they were encountering.
Embedded materials or embedded resistors are normally a Ticer material. The customer was calling out a specific PCB stack-up that required Rogers material as well. This specific Roger material being called out had very long lead times, which prohibited us from meeting their need date.
So, we came back to them with another solution: what if we make the material in-house? After offering this solution that they did not think was possible, we were able to achieve what they were looking for. Making this material is something we do on a regular basis, so we were able to meet their dielectric that they needed and meet the due date.
Illustration of embedded resistors in a PCB stack-up.
This high-tech circuit board was a hybrid build, with a specialized high-speed material manufactured to meet their needs, along with the embedded resistor material.
Not only did we have the capability in-house to build embedded resistors, but we also had the ability in-house to 100% test every single resistor embedded the PCB. We were able to come up with a solution for specialized materials and material lead times and were able to meet their delivery time. Not only did we ship it early, but all parts were already tested and found zero issues.
Result
The advantage for this customer is they now have a partner that they know can deliver embedded resistors material or embedded resistor PCB parts. They were so happy with the quality and delivery of these circuit boards, they gave us a purchase order to acquire the types of materials needed, and stock it on the shelf for future products with them.
Normally when talking about this technology, it allows the customer to gain space on the asset, so if you are thinking of resistors, putting it inside the board is a solution not many people think about. With our solutions, it allowed the customer to be more flexible and quicker to market because we're quicker and we've given them options like putting material on the shelf so that we can even improve the lead time even more.
And most importantly, they no longer have quality issues.
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