Introduction: The Day We Picked the Wrong Flexible Board—And Cost the Client $10,000 Last quarter, my team was designing a control module for a heavy-duty construction crane. We needed a flexible b……
Introduction: The Day Our Car Dashboard Became a “Wire Maze”—And FPCs Unraveled ItLast year, my team was tasked with designing a luxury car’s dashboard featuring three screens: a 12-inch main infotain……
Introduction: The Day Our Foldable Phone PCB Snapped—And We Learned to Design for Flex Last year, my team was testing a prototype for a foldable phone with a rigid-flex PCB. We’d spent months perfe……
Introduction: The Day Our Rigid-Flex Mass Production Hit a Wall—30% Yield, 70% Waste Last year, my team finally moved our rigid-flex PCB design for a smart thermostat into mass production. We’d spe……
Introduction: The Day We Realized Our Sensor Wiring Was Bleeding Money Last year, I was on-site at a manufacturing plant in Texas that used our industrial temperature sensors. The plant manager, Ca……
Introduction: The Day Our Gimbal Froze—Rigid Wires Were to BlameLast spring, our team tested a new drone gimbal. Mid-flight, it froze—camera tilted, forcing an emergency landing. Tearing it apart, we ……
Introduction: The Day Our Poolside Speakers Died—All Because of HumidityLast summer, my team launched a line of waterproof poolside Bluetooth speakers. We tested them in our lab: submerged in 1m of wa……
Introduction: The Day We Had to Choose—Rigid-Flex or Traditional PCB (And Cost Was Everything)Last quarter, my team was designing a portable Bluetooth speaker for a client. The speaker needed to be sl……
Introduction: The Glucose Monitor That Couldn’t Fit—Until We Combined Two TechsLast year, my team struggled to build a postage-stamp-sized glucose monitor. We needed a battery, sensor, microcontroller……
Introduction: The Day Our Wireless Earbuds Started Falling Apart—One Solder Joint at a TimeSix months ago, my team launched a pair of wireless earbuds—sleek, lightweight, and packed with features. We ……
Introduction: The Day a Radar Sensor Failed—And Rigid-Flex PCB Was the FixLast winter, a fleet of delivery trucks in Michigan started having a strange problem: their adaptive cruise control (ACC) kept……
Introduction: The Day Our Smartwatch Design Hit a Wall—Thanks to Rigid PCBsTwo years ago, I led a team designing a slim smartwatch for fitness enthusiasts. Our goal was simple: a 6mm-thin device that ……
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