Circuitwise capability Archives

Why robust test systems are critical to manufacturing reliability

Manufacturing success depends on deliberate planning, not reactive correction. Too many manufacturers still treat testing as an afterthought once products reach production. That mindset overlooks the strategic role of test systems in preventing costly failures. A structured manufacturing plan that includes test development from the outset helps manufacturers identify risks, strengthen processes, and produce consistent, high-quality outcomes.

A mature manufacturing plan is essential for high-risk or regulated markets and should include a process failure mode and effects analysis (pFMEA). This framework detects and mitigates potential failures before they occur, protecting against the release of inadequately tested products that lead to field returns, warranty claims, and reputational harm. It also creates a foundation for accountability by guiding quality actions such as test coverage, traceability, and validation.

Design rigour underpins effective testing. Front-loading design with realistic component tolerances, thermal margins, and interface timing creates the right conditions for quality manufacturing. Integrating firmware with hardware interfaces supports accurate diagnostics and early fault detection. The ability to capture, measure, and analyse data in real time is essential because products that aren’t measured or monitored mature only through costly field feedback.

What’s often overlooked is just how many field failures are preventable. In our experience, more than 90 per cent of field issues can be easily foreseen and avoided with the right design discipline and test systems in place. Almost every defect we’ve encountered across countless root-cause investigations has been traceable to something that could have been detected earlier with the right checks, diagnostics, or validated assumptions. This doesn’t reflect poorly on engineering teams; however, it does prove that robust test planning works, and that failures rarely occur without warning signs.

Key principles of effective test system integration

Manufacturers need to integrate test strategy early and deliberately to build reliability into every stage of production. Core principles include:

Embedding test facilities during design transfer to support readiness before the first production run.
Aligning test procedures with end-user specifications so performance expectations are validated, not assumed.
Using standardised, repeatable methods for consistency, traceability, and auditability.
Automating test processes where possible to improve accuracy, reduce human error, and accelerate throughput.

How Circuitwise strengthens reliability through advanced test systems

Circuitwise applies these principles by integrating test system development directly into its manufacturing services. We work collaboratively with our customers to design for testability, putting every product through robust validation before shipment. This proactive approach mitigates manufacturing ambiguity, accelerates fault resolution, and reduces risk exposure. It delivers confidence that products will perform as intended reliably, repeatedly, and at scale.

This includes:

1. Automated Test Equipment (ATE) for high reliability builds where speed, repeatability, and diagnostic depth are essential

Circuitwise uses automated test equipment ATE to ensure every assembly is verified consistently and accurately before release. Our ATE platforms combine controlled electrical stimulus, automated measurement, and data capture to validate that each unit performs to specification. By automating these steps, we remove operator variability, improve throughput, and detect issues earlier in the process. All test data feeds into our traceability systems, supporting audit requirements and device history files across regulated industries ensuring that functional performance is checked the same way every time.

2. Custom test jig design tailored to suit each product’s electrical, mechanical, and firmware characteristics

We design and build custom jigs and fixtures to support in-circuit testing (ICT), functional testing (FCT), and reliable programming interfaces. Each fixture is engineered to provide stable electrical contacts, correct mechanical alignment, and safe, repeatable engagement with the PCBA. Because these are developed in-house alongside the test plans, they form a validated and scalable part of the manufacturing process ensuring every unit is tested consistently before release.

3. Test coverage optimisation that confirms every critical function is measured, validated, and documented

We work with customers to confirm that every critical function is measured, validated, and documented. This approach reduces ambiguity, supports fault isolation, and strengthens confidence in long-term performance and reliability.

Quality systems built for regulated industries

We operate under a comprehensive quality management framework certified to ISO 9001, ISO 13485, AS 9100D and ISO 14971 standards.

ISO 9001 supports consistent quality management across all projects.
ISO 13485 addresses medical device manufacturing requirements for compliance with Therapeutic Goods Administration (TGA) and U.S. Food and Drug Administration (FDA) expectations.
AS 9100D extends ISO 9001 with additional requirements for aerospace and defence manufacturing, including configuration management, traceability, and risk-based decision-making.
ISO 14971 international standard that specifies the process for risk management for medical devices throughout their entire life cycle, including manufacturing

We also adhere to IPC Class II and Class III workmanship standards for printed circuit board assemblies (PCBA). These standards meet the strictest acceptance criteria for reliability and durability.

Quality built in, not tested in

The lesson is simple: most field failures can be avoided. Integrated test systems, disciplined design work and automated validation set the foundation for reliable products. Companies in MedTech, Aerospace, Defence, and Industrial sectors need products that perform the first time and every time, so testing needs to be built into the manufacturing plan from day one.

We are the trusted manufacturing partner when reliability and safety are critical, thanks to our continuous improvement culture, advanced automation, and rigorous testing framework.

What other industries can learn from medical-grade manufacturing

You can’t afford failure when your products are expected to perform under pressure in high-stakes environments like Defence, Aerospace, and Industrial sectors. Too often, manufacturing standards are set by what’s acceptable, not what’s essential, and there’s a growing need to rethink what quality looks like in critical sectors.

However, there’s one sector that’s been quietly setting the benchmark: medical manufacturing. Medical technology (MedTech) manufacturing demands absolute reliability, with systems built so that every product performs flawlessly from the outset. This commitment to precision, traceability, and accountability sets a standard that other industries can learn from. Medical manufacturing follows principles from how you manage risk to how you inspect, document, and deliver, that offer a blueprint for building higher performing, more dependable products, no matter the application.

There are four clear, transferable lessons that Defence, Aerospace, and other high-reliability industries can take from medical-grade manufacturing.

Risk tolerance is lower than you think

Failure isn’t an option in medical devices. That same principle should apply across many non-medical sectors, yet it often doesn’t. The assumption is that healthcare is uniquely sensitive and that other applications can afford some margin of error. However, the reality is that the operational and reputational cost of failure in Defence, Aerospace, and Industrial sectors like mining is just as high. A failed circuit board in an unmanned aerial vehicle (UAV) or industrial robot can delay operations, damage assets, or worse.

What medical-grade manufacturing does well is eliminate the question of risk tolerance. There’s no ‘we’ll catch it later’ mentality. Everything is built and tested to perform as expected the first time. Extending that approach to other industries gives you more than compliance. It provides assurance. Your products become more robust, and your team spends less time firefighting.

Traceability and documentation are your insurance policy

Your ability to act fast when a fault occurs depends entirely on what you can trace. Unfortunately, this means limited insight in most manufacturing environments as your recall scope is wider if you’re only tracking batches and not individual components. And, if your documentation is incomplete, your investigation slows down. Medical-grade practices solve this by providing full traceability for every component on every board, with complete documentation from assembly through to final inspection.

This level of detail may seem excessive if you’re used to faster, looser production cycles. However, traceability and documentation become invaluable if an issue surfaces. It lets you isolate problems to specific parts or batches, demonstrate compliance to external stakeholders, and respond with confidence quickly. That’s not just a nice-to-have; it’s a strategic safeguard in sectors where your product may one day be subject to legal, technical, or regulatory scrutiny.

Sampling is a gamble you don’t need to take

Some manufacturers rely on sample-based quality control to save time and cost, but sampling can introduce risk in low- to mid-volume, high-complexity builds where defects aren’t always evenly distributed. Skipping verification steps becomes a liability, not an efficiency, if your product must work without exception, especially in applications where performance is mission critical.

In medical manufacturing, consistency and traceability are non-negotiable. Every assembly is produced under validated conditions, every test result is documented, and every anomaly is investigated. This level of control makes defects traceable and solvable, instead of hidden and systemic. Moving beyond sampling gives you near-absolute assurance, and that’s a powerful position to be in.

Good enough is no longer good enough

It’s time to reframe your thinking if you’ve ever been told that ‘good enough’ will do. Medical-grade manufacturing prioritises validating that what goes out the door performs exactly as intended. That doesn’t just help in extreme environments; it adds value at every level of your operation. The result is that your support team spends less time managing failures, your engineers spend less time redesigning for quality, and your customers develop stronger trust in your brand.

Circuitwise has built its entire process around this philosophy. Every customer we work with benefits from the same quality management system that governs our high-reliability production of medical devices. That means no corner-cutting, no shortcuts, and no separate standard for non-medical products. Our experience is that anything worth building is worth building right, and the customers we work with agree.

Make quality a non-negotiable, not an upgrade

The real lesson from medical-grade manufacturing isn’t just about processes. It’s about priorities too. Adopting the same principle across sectors like Aerospace, Defence, and industrial applications leads to better products, more predictable outcomes, lower risk exposure, and a stronger reputation with customers.

Regardless of whether your products are going to market under regulatory pressure or not, you can still choose to hold them to a higher standard. You can choose a manufacturing partner that doesn’t distinguish between a surgical device and a satellite component, and you can choose to treat reliability as a baseline, not a differentiator. That’s how you stay ahead in industries where trust, performance, and repeatability matter, and it’s exactly what medical-grade manufacturing has been doing for decades.

Circuitwise treats every project with the same standards we apply to manufacturing life-saving medical devices, whether you’re building a communication module for defence or a sensor for mining. We apply full component traceability with rigorous inspection and testing at every stage, because anything less introduces risk. This level of quality isn’t a value-add; it’s a mindset shift that can give your business greater control, faster fault isolation, and deeper confidence in every product that leaves the line.

Contact Circuitwise today to speak to a partner that is committed to manufacturing products that work the first time, every time, across MedTech, Aerospace, Defence, and Industrial sectors.

Component traceability for medical devices

Traceability of the components is a critical part of the quality assurance processes required to gain regulatory approvals for medical devices.

The ISO 13485 Quality Systems Standard for Medical Devices requires that the product owner shall “plan and develop the processes needed for product realization” including “traceability activities specific to the product together with the criteria for product acceptance”.

The company needs to document procedures that define the extent of traceability required for applicable regulatory requirements and what records need to be maintained. The standard specifically requires an organisation to “maintain records for each medical device or batch of medical devices that provides traceability for each”.

Most companies developing medical devices with electronic components will outsource Printed Circuit Board Assembly (PCBA) to a contract electronics manufacturer like Circuitwise that has ISO 13485 certification.

Traceability means the manufacturer needs to keep track of where every single component has come from and where it goes. This information is stored as part of the Device History Record that the product owner must maintain.

Most medical devices are Class IIa or Class IIb and implementing traceability at the batch level is usually sufficient. However, for applications where correct operation of the device is critical to sustaining or supporting a patient’s life (Class III), product manufacturers will ask for traceability at the device level. See the blog post on our contribution to development of emergency ventilators as an example.

Tied in with traceability is the concept of identification. Each component and each assembled product must have a unique identifier so that only products that “have passed the required inspections or testing is released for dispatch, use or installation”.

At Circuitwise, every PCBA has a serial number that facilitates our ability to keep records which components are used on any particular board. This ability is enabled by the Cluso inventory management system developed in-house at Circuitwise and now exported globally.

The main steps in the PCB assembly process where traceability is critical are as follows:

Incoming goods inspection and acceptance: Every part (including reels of parts or other packaging formats) entering the Circuitwise factory is photographed and a serial number attached. We check what we received is what we ordered and capture supplier information.
Storage of components: Parts are stored in the Cluso smart storage system that facilitates easy and accurate retrieval of components from thousands of reels on the shelves. Each component is logged as it goes onto a shelf and the system ensure first in is first out.
Pick and place production: As components are retrieved from the smart storage and allocated to the pick and place machines, they are again logged. Serial numbers are assigned to PCBs and captured in the Cluso system. A range of other information in captured during preparation for a production run including ensure the correct stencil is used, the lot number of the solder paste, its shelf life, temperature of the paste, last maintenance date of the paste printer, what version of Pick and Place program placement is used etc.
Reflow: As the assembled PCB passes through the reflow oven, we record the temperature profiles used in the oven.
First article inspection: The first PCBA is inspected to ensure it is 100% correct. This is used as a golden board for Automated Optical Inspection. A report of this first inspection is recorded.
Automated Optical Inspection: Although not strictly necessary for medical devices, we maintain records of the AOI inspection of each PCBA.
Through hold parts assembly: If the PCBA requires additional placement of through-hole components, then a similar traceability checks and records are undertaken as for the pick and place process.
Electrical testing: As firmware is uploaded, its version number is recorded. After upload, very board undergoes electrical and functional testing to ensure it is working correctly. Records of the tests are entered into the Cluso system.
Conformal coating: Were conformal coating or other processes are required to finish off the boards, records are again taken.
Final assembly: Where Circuitwise assembles the final product the mechanical components are put through the same traceability regime to ensure every part is traced through to the final product.
QC inspection: Prior to shipping the device undergoes a final quality control inspection, with procedures provided by the product owner. Records of the inspection are taken and certificates of conformity are issued.
Packaging: Traceability is required in every aspect of the product delivery process. So again records are taken of the packaging used and any additional items included in the box, such as instructional materials. Where necessary, photographs are taken to prove all necessary items were present as the box was sealed.

Computer monitor displaying side-by-side comparison of a printed circuit board design during first article inspection, highlighting differences for quality control. — Above is an image of a board being compared to a customer design. During each run, we inspect the first board to ensure it is 100% correct – producing a golden board. Our unique first article inspection system automates the process of comparing the golden board against the design supplied by the customer.

Technician holding a temperature profiling device connected to a printed circuit board wrapped in protective yellow Kapton tape for reflow oven calibration. — *Above is an example of a new PCB assembly rigged up with sensors and ready for profiling. We use this to optimise the temperatures in the reflow ovens. More on our PCB assembly testing services.*

Technician operating a Saki automated optical inspection machine, checking printed circuit boards against design specifications on a computer screen. — Above is our Saki PCB optical inspection machine. We use Saki and Yestech machines for autonomously inspecting each board coming off a run against the golden board. We check for shorts and opens, solder joints and other joint defects with reference to IPC 610. We ensure the correct components are in place including polarity and location.

Printed circuit board secured in an electrical testing fixture with multiple probes for in-circuit testing. — Above is an example of an electrical testing device. More on electrical testing. We conduct in-circuit testing that checks for shorts and opens in the circuit board tracks as well as the values of basic components such as resistance, capacitance and inductance. These tests are typically conducted using a bed-of-nails tester supplied by the electronics designer.

Functional testing setup for printed circuit boards, with multiple boards connected to diagnostic equipment and measurement tools. — After uploading firmware, we conduct functional testing to verify the device is working as intended, using a testing system supplied by the designer. We can also stress-test the device by conducting these tests at high and low temperatures and cycling between these extremes. The environmental chamber can also test devices in high humidity conditions.

This rigorous system generates many traceability benefits. For example, if a component is sensitive to moisture, it is placed in a dry cabinet until it is ready to be used. When it is taken out of the cabinet, the reel is scanned and the time it is out of the cabinet is logged. In this way, if there is ever a problem with moisture sensitive components in the field, we can provide evidence that the component’s exposure to moisture before manufacture was fully controlled.

Another benefit is that the operator using the Cluso system is automatically logged. So we know which operator took a reel from storage and placed it in the pick and place machine. If there is an error with either the system or with the operator following procedures correctly, we can take corrective action – which is the essence of a quality system.

For more information on other aspects of quality systems required for electronic medical device manufacturing review our MedTech Manufacturing Services.

Next-level PCB prototyping launches at Circuitwise

In product development, speed to market while maintaining quality is critical. That’s why the Circuitwise Group has invested in a major upgrade of its PCB prototyping capabilities by installing a brand-new multi-function pick-and-place prototyping machine. This cutting-edge platform allows product developers to rapidly iterate their designs, allowing testing to detect any errors before committing to volume production.

The technology we have chosen is the Europlacer’s inneo+, which has unmatched versatility in the range of components it can handle. In traditional SMT pick-and-place systems, different placement heads may only be capable of handling specific component types, requiring longer setup times. By contrast, the iineo+ has “smart nozzles” that can handle the full range of components, significantly improving prototyping speed.

Design for Manufacture feedback on PCB prototypes

Whether a printed circuit board (PCB) prototype includes standard parts, odd-form components, or intricate designs, Circuitwise can now ensure seamless, accurate placement across all prototype iterations. This versatility allows product developers to push the boundaries of their designs while gaining valuable Design For Manufacture (DFM) feedback from Circuitwise.

Key DFM feedback relates to a range of factors including issues around component placement, manufacturing tolerances, thermal management, assembly line efficiency, soldering quality, testing procedures, BOM optimisation, and process documentation for quality assurance. Prototyping allows the design to be fine-tuned across all these factors and more prior to committing to volume production.

A step up in prototyping capability

As part of our continual improvement ethos, Circuitwise always aims to exceed industry standards to provide the highest quality possible. Our selection of the iineo+ is the latest in a recent series of capability upgrades to put us at the forefront of electronics manufacturing.

The iineo+ delivers almost unlimited configuration options, handling virtually any component and a wide range of board sizes, including large substrates up to 1610mm x 600mm. The platform has a rotary turret head with 12 smart nozzles. The addition of digital vision, integrated intelligence, and linear motors work together to ensure high-speed, high-precision placement for all components.

Where all the PCB prototyping action happens inside our pick-and-place machine — Where all the prototyping action happens inside our pick-and-place machine

Several other features support the flexibility and speed. The platform provides 264 positions for 8mm tapes, an internal waffle tray zone for ten JEDEC trays, a built-in component electrical tester, intelligent feeder carts and more. For special assembly applications, options include glue dispense, a fixed camera for large devices, stock management, multi-program optimisation, NPI, and a traceability upgrade option that includes a live production dashboard and auto-width conveyor.

Regarding speed, the winning feature is the ability to “balance” the platform’s operation during prototyping. With ordinary prototyping machines, there is always a bottleneck where manual intervention is required due to some limitation. The smart features of this machine and the versatility in component placement mean the platform can be fully balanced for any prototyping run.

Enhancing our obsession with quality in PCB Prototyping

One of the machine’s standout features is its 3DPS (Three-Dimensional Placement Sensing) technology, which offers closed-loop control of the forces applied during component placement. This level of control is critical in ensuring consistent placement accuracy across every prototype iteration, no matter the complexity of the board design.

By eliminating common issues such as component misalignment or improper soldering, Circuitwise can deliver prototypes that are close to what the production version would look like, if not identical. For product developers, this translates into fewer surprises during production and a smoother transition from prototype to final product.

Circuitwise’s installation of the Europlacer iineo+ pick-and-place platform sets a new standard for PCB prototyping in Australia. We have always provided a quality prototyping service, but this investment extends our obsession with quality from the production phase to the prototyping phase. As a partner in innovation, Circuitwise is committed to supporting its customers through every phase of product development.

This equipment was purchased with the support of a Supply Chain Resilience grant from the Australian government.

The Circuitwise Group includes Circuitwise Electronics Manufacturing in Sydney, Australia and Nautech Electronics

Laser marking for improved PCB traceability in electronics manufacturing

Quality control is at the heart of everything we do at Circuitwise, and one of the most critical aspects of this is traceability—knowing exactly where every component goes in the production process. Traditionally, this is achieved by uniquely identifying each printed circuit board (PCB) assembly with a barcode or QR code, typically applied using an adhesive sticker. While this method is adequate for many applications, we believe there’s always room for improvement when it comes to quality.

Demonstration of laser marking with the Circuitwise logo

That’s why we’ve taken an extra step by investing in an Laser Marking System, a state-of-the-art solution that ensures unparalleled durability and precision in component identification. Unlike adhesive labels, which can peel off, fade, or be compromised by heat and chemicals, laser marking offers a permanent solution. The unique code etched into the surface of the PCB assembly is not only immune to aging and environmental factors but also guarantees that traceability is maintained throughout the product’s lifecycle.

Laser-enabled traceability requires advanced equipment

The system we chose is the Youngpool M2-900 which is highly versatility and efficient. This advanced system supports up to four types of lasers—CO2, UV, Green, and Fibre—ensuring optimal performance across different materials and applications. Whether we’re marking 1D and 2D codes, text, logos, or optical characters, the M2-900 delivers high-quality results every time.

Circuitwise's laser marking traceability system — Circuitwise’s laser marking system

In addition to its precision, the technology enhances throughput and flexibility on the production line. Its dual-head configuration allows for simultaneous top and bottom marking, while the dual-camera setup ensures both reading and marking occur at the same time, significantly speeding up the process without compromising quality. For projects that demand even greater efficiency, an optional dual conveyor configuration is available, further boosting throughput.

Safety and environmental responsibility are also key considerations in our operations. The M2-900 is equipped with a safety enclosure and interlock switches that prevent pollution of the shop floor, ensuring a clean and safe working environment. The system also comes standard with a separate dust collector and fume detection, making it easy to maintain while minimizing its impact on the workplace.

We are committed to delivering the highest quality products, and our investment in this advanced Laser Marking System is just one example of how we go above and beyond to meet and exceed industry standards. By integrating cutting-edge technology into our processes, we not only ensure the integrity and traceability of every component but also reinforce our dedication to innovation and excellence in electronics manufacturing.

Space ready coating comes to Circuitwise

When applying coatings in electronics manufacturing, precision is everything—especially when it involves connectors, earth pads, and components like switches that must remain uncoated. Traditionally, this meticulous task required manual masking, a time-consuming process that demanded intense focus and care.

Circuitwise is thrilled to announce a significant leap forward in our manufacturing capabilities with the recent installation of an automated coating line and media application in several different applications.

The technology can be used for everything from building 3D structures, dam and fill protection, sealing enclosures, glob top spot protection, flip chip underfill, encapsulation and application of heat transfer media.

Conformal coating

The primary application is conformal coating. This cutting-edge technology revolutionizes our coating process, utilizing advanced nozzles and a fiducial camera to apply a flawless, uniform layer of coating precisely where it’s needed—eliminating the need for manual masking.

But we didn’t stop at just coating. The new coating system is positioned in a production line packed with advanced equipment, both upstream and downstream, as shown below:

A magazine loader is used to efficiently load large numbers of PCB boards onto the conformal coating production line. With selectable pitch settings, stepper motorised pushing and more, this machine helps make your manufacturing process as efficient as possible.

Circuitwise selected the Protecto XP V4 Automated Conformal Coating System from Rehm Group. It’s packed with advanced features such as a heatable nozzle that guarantees a constant lacquer temperature, automatic needle measurement checks and automatic self-cleaning during downtime. It’s optimised for maintaining high quality, even for low volume production.

A UV inspection machine examines the PCBs under ultraviolet light, fluorescing the coatings allowing cameras to capture and inspect high fidelity images for any irregularities. This ensures adequate coating thickness with no gaps and surface coverage in all the targeted areas.

The new line also includes an inline infrared oven for speeding up the curing process under environmental control to ensure an optimal bond with the PCB and that no quality issues arise from dust or moisture.

A magazine unloader completes the line, ensuring efficient unloading of large numbers of PCB boards. An arriving PCB is taken up by the attached conveyor and then pushed into the magazine by a specially designed pusher. The magazine indexes to the next position and is ready for the following unloading cycle.

What we can learn from Apollo 13 about conformal coating

Installation of the conformal coating reminds us of an early blog we published about a fascinating scene in the iconic movie Apollo 13. In the scene, the astronauts are repowering the electronics of their capsule after a few days of freezing temperatures when all the electronics have developed a nice coat of frost. There is a tense moment as the control panels warm up with water dripping off them before the spacecraft successfully comes back to life. Without knowing the details of Apollo 13’s electronics, it is safe to say they probably had some form of conformal coating, allowing them to operate in such wet conditions.

Photo Credit: NASA (via Wikimedia Commons) – This photo from training for the Apollo 16 mission shows some of the electronics. Pictured is Ken Mattingly (right foreground), during extravehicular activity training at NASA’s Manned Spacecraft Center. Mattingly was scheduled to fly on Apollo 13 but was replaced by Jack Swigert (see below) after he was potentially exposed to German Measles.

Fast forward to 2022 as the Internet of Things technology mega-trend continues, we are seeing electronics being deployed in an exponentially increasing variety of locations, often exposing them to harsh environments, including a burgeoning space industry. Conformal coating is the go-to option for improving the performance of PCBAs and prolonging their life span in such conditions.

There are many reasons to use conformal coatings including:

Preventing arcing and allowing tighter designs
Inhibiting corrosion
Resistance to fluids and high humidity
Protection from temperature extremes
Abrasion resistance
Soften and protect sharp edges

Overall conformal coatings increase reliability against extremes in environmental conditions and lengthens the life of the product. In addition, as the coatings form a very thin film, typically around 50 µm thick, “conforming” easily to the irregular contours of the substrate, there is minimal effect on the weight of the component.

Jack Swigert (right) prepares to enter spacecraft for altitude chamber test for the Apollo 13 mission – September 1969. Source NASA (https://www.hq.nasa.gov/alsj/a13/images13.html)

There are several types of resin to choose from including acrylic, silicone, epoxy, urethane and parylene. Acrylic is the most popular as it’s easy to apply, does not shrink and is most affordable. It is easily removed with solvents to facilitate rework but that makes them unsuitable for environments where they may encounter unwanted solvents. For chemically harsh environments, polyurethane coatings provide better protection. Epoxy coatings are ridged and generally used in physically harsher applications. Silicone has better insulating properties so better for exposure to high temperatures above 150°C.

The astronauts of Apollo 13 probably owed their lives to someone who paid attention to conformal coating and today we need to take the same attitude to any product in harsh environments.

Circuitwise is proud to invest in state-of-the-art technology to provide our customers, especially those developing devices for aerospace, medical and space applications, with the best possible service.

This equipment was purchased with the support of a Supply Chain Resilience grant from the Australian government.

Minimising mechanical stresses on Printed Circuit Boards (PCB) with a depaneling router

Circuitwise is thrilled to announce a significant upgrade to our production capabilities with the installation of an advanced Automated PCB Depaneling Router. This cutting-edge technology is a game changer for improving the smoothness and mechanical integrity of the finished PCB, while delivering unparalleled precision and efficiency.

Depaneling is the process by which individual PCB assemblies are removed from a panel coming off the production line. Traditionally, removing PCBs from panels is a manual process, relying on mouse bites or V-grooves, that can result in rough edges and compromised board integrity. Protruding edges at the snap off point can make fitting the PCB into highly constrained enclosures difficult.

Our new router eliminates these issues, ensuring that every PCB emerges with a flawless finish. Using a router bit to mill the material ensures a precise edge for the PCB, giving designers the confidence to use all space right to the board’s edge. In addition, routing avoids mechanical stresses on the PCB lamination and components, otherwise caused by the PCB being snapped out of the panel.

Our new router is a versatile tool, capable of handling a wide range of PCB sizes, and is particularly helpful for small odd-shaped boards designed for constrained spaces.

The machine is equipped with a dual high-speed camera auxiliary programming system, making programming easier. A high-speed CCD vision automatic correction system greatly improves the cutting accuracy and operation efficiency. A high-speed spindle delivers low splitting stress and high precision, and it is suitable for any shape of circuit board. The machine has dual-table movement so it can cut two different products and place the circuit board at the same time, improving efficiency.

Circuitwise is proud to invest in state-of-the-art technology to provide our customers with the best possible service. Contact us if you want to understand how this equipment can be used with your product. This equipment was purchased with the support of a Supply Chain Resilience grant from the Australian government.

Electronics manufacturing quality starts with automated optical inspection

Circuitwise recently purchased a new 3D Automated Optical Inspection (AOI) machine from Cyberoptics (recently acquired by Nordson), which will double down on our already high attention to detail, and improve efficiency of our two main production lines. This follows the purchase of our first AOI machine late 2022.

AOI scans assembled PCBs coming off the production line to identify errors. At a high level, it identifies obvious problems like missing or misplaced components. However, this machine can inspect every aspect of a PCB assembly with microscopic precision, enabling difficult to detect soldering issues and more. This will enable Circuitwise to catch production issues early and adjust processes to ensure optimal quality.

Importantly, this machine enables inspection at Class 2 and 3 standard, for products requiring those levels of assurance. It also includes advanced technology that eliminates inspection mistakes caused by reflections off shiny components and solder joints, allowing Circuitwise to maintain high speed production without any loss of quality.

Circuitwise is proud to invest in state-of-the-art technology to provide our customers with the best possible service. This equipment was purchased with the support of a Supply Chain Resilience grant from the Australian government.

Automating conformal coating for PCB electronics manufacturing

When applying a conformal coating to connectors, earth pads, and specific components like switches, attention to detail is critical as they should not be coated. They are normally masked off manually, which is a laborious process with high attention to detail required.

Circuitwise recently invested in a Protecto XP V4 Automated Conformal Coating System from Rehm Group. This technology greatly improves the reliability of the coating process by using high-performance nozzles and a fiducial camera that precisely deposits a homogeneous film layer only where required, avoiding the need for masking.

The conformal coating machine was paired with a UV inspection buffer, which examines the PCBs under ultraviolet light to ensure adequate coating thickness with no gaps and surface coverage in all the designated areas. The new line also included an inline drying machine to speed up the drying process under environmental control to ensure no quality issues arising from dust or moisture.

Circuitwise formally certified for QMS requirements for Aviation, Space and Defence industry.

Obtaining a New Certificate of Registration: Circuitwise Adopts AS 9100D Quality Management System Drive Towards Excellence in Aerospace Manufacturing.

For companies operating in industries such as aerospace the need for quality, reliability, and safety is non-negotiable. It is with this goal in mind that we, Circuitwise, a leading electronics manufacturing services provider, is proud to announce our latest achievement of a new Certificate of Registration for its Quality Management System (QMS) which complies with the requirements of AS 9100D.

What is AS 9100D? AS 9100D is an internationally recognized Quality Management System standard specifically tailored for the aerospace industry. Developed by the International Aerospace Quality Group (IAQG), AS 9100D establishes a robust framework for organizations to manage quality, risk prevention, and product safety in their manufacturing processes. This certification reflects Circuitwise’s commitment to adopting best practices, complying with industry regulations, and delivering the highest quality products and services to its aerospace customers.

Benefits of AS 9100D Certification: Achieving AS 9100D certification is a significant milestone for Circuitwise. This certification brings numerous benefits that will help its customers in the aerospace industry. Some of the key benefits include:

Enhanced Confidence: AS 9100D certification assures Circuitwise’s customers that the company is dedicated to meeting their specific needs and requirements. It demonstrates a commitment to continuous improvement and customer satisfaction, which builds trust and confidence in the company’s capabilities. Many aerospace companies and government organizations require suppliers to have AS 9100D certification to ensure that stringent quality standards are met.
Improved Process Efficiency: The AS 9100D standard focuses on process efficiency and risk management. By implementing this QMS, Circuitwise can streamline its processes, identify areas that require improvement, and mitigate risks effectively. This leads to increased operational efficiency, reduced waste, and optimized resource utilization.
Continuous Improvement and Compliance: Certification to AS 9100D is not a one-time achievement but an ongoing commitment to continuous improvement. Circuitwise will regularly assess and improve its processes to maintain compliance and achieve the highest standards of quality, safety, and customer satisfaction.

By obtaining the AS 9100D certification, Circuitwise demonstrates its dedication to maintaining the highest level of quality management practices across its operations. This certification strengthens the company’s position as a reliable and trustworthy partner in the aerospace industry. It provides assurance that Circuitwise’s products and services align with the stringent requirements of customers, regulatory bodies, and industry standards.

Circuitwise’s new Certificate of Registration for operating a Quality Management System that complies with AS 9100D is a testament to its continual commitment to excellence in the aerospace manufacturing industry. This certification not only reaffirms its focus on providing top-quality products and services but also positions the company as a preferred partner for aerospace organizations worldwide. Circuitwise’s dedication to meeting and exceeding customer expectations, mitigating risks, and driving continuous improvement sets a benchmark for other industry players. With the AS 9100D certification, Circuitwise continues to soar to new heights, leading the way in delivering excellence in aerospace manufacturing.

For more information and a case study, see our Aerospace webpage.