2024 Season Wrap-Up of the Reliability Matters Podcast

Today we’re celebrating the end of another incredible year.

This isn’t just any episode—it’s a time to reflect on the journey we’ve been on together, highlight some milestones, and share a heartfelt thank you to everyone who has made this podcast such a success. Can you believe it?

Reliability Matters has now released 159 episodes! It feels like just yesterday we started this podcast with the mission to explore how industry experts and their knowledge contribute to the reliability of electronics. And here we are—growing, learning, and making a real impact in our field.

But here’s what blows me away the most: over 85,000 downloads. That’s not just a number—it’s a testament to you, our amazing audience.

Whether you’re listening in your car or on your morning jog, or watching this on our YouTube channel, you’ve made this podcast part of your journey. And for that, I’m deeply grateful.

This year alone, we’ve covered some fascinating topics. From ultra-high-density interconnects to post-reflow inspection, from thermal profiling to cutting-edge coating materials—we’ve explored it all. Along the way, I’ve had the privilege of sitting down with some of the brightest minds in the electronics industry.

Each guest has brought their unique insights, helping us all better understand the intricate science and art behind building reliable electronics.

To my incredible guests—thank you. Your willingness to share your expertise, stories, and even a few laughs has been the lifeblood of this podcast. Every episode is a reflection of your generosity and brilliance.

I also want to give a shout-out to you—yes, you. Whether you’re a long-time listener or you just discovered us this year, you’re the reason I do this.  The messages, the comments, the emails—it’s all so inspiring. When you tell me how a particular episode helped solve a problem, spark a new idea, or simply make your day better, it reminds me why Reliability Matters matters.

As we wrap up the year, I’m reminded of something I say often on this show: reliability isn’t just a goal; it’s a journey. It’s a series of choices, processes, and innovations that, together, ensure the technology we rely on lives up to its promise.

And this podcast? It’s a part of that journey. It’s a space where we can learn together, challenge assumptions, and stay ahead of the curve in an ever-evolving industry.

Mike Konrad’s Contact Info:
mike@mikekonrad.com
https://www.reliabilitymatterspodcast.com

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The New Kids in Town – The Cast of the D-Code Podcast

Today, I’m excited to introduce the hosts of the D-Code podcast, a dynamic trio of young professionals making waves in the electronics manufacturing industry.

With experience rooted in contract manufacturing and stencil fabrication for electronic assemblies, they bring a fresh perspective to the table. Although they’re at the start of their podcasting journey, D-Code has already begun to attract attention, tackling industry insights with a unique lens that up-and-coming voices can uniquely offer.

My guests today are Daniel Stanphill, SMT Process Engineer at Aurora Boardworks, a contract assembler located in Aurora, Nebraska, Sean Kincaid, President of K & F Electronics, located in Fraser Michigan, also a contract manufacturer, and Elias Malfavon, President of Metal Etch Services, a SMT stencil fabricator located in San Marcos California.

I’ll ask them about their experiences, challenges, and how they’re setting out to decode the world of electronics manufacturing.

Contact Information:
The D-Code Podcast
https://www.youtube.com/@The-D-Code

Daniel Stanphill
Aurora Boardworks
daniel.stanphill@auroraboardworks.com
https://auroraboardworks.com

Sean Kincaid
K & F Electronics
sean@the-d-code.com
https://www.circuitboards.com

Elias Malfavon
Metal Etch Services
elias@the-d-code.com

Home

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What’s On Your Workbench? Critical Steps to Avoid Contamination of PCA’s During the Rework Process

On today’s episode, we’ll be exploring the critical steps to avoid contamination on circuit assemblies during the rework process with our expert guest, Gayle Towell.

Gayle is the Content Marketing Specialist at AIM Solder, a leading global manufacturer of solder assembly materials for the electronics industry. She holds master’s degrees in both mathematics and physics from the University of Oregon and has nearly two decades of experience in higher education, technical writing, and creative writing.

In her role at AIM Solder, Gayle is instrumental in producing technical and research-based materials, while also collaborating with industry partners on various projects.  She has contributed articles to industry publications, such as the Printed Circuit Engineering Association Magazine, where she discusses topics like solder paste powder sizes and mixing methods.

Gayle has also participated in industry events, including the SMTA International conference, where she shared her expertise in sessions covering soldering technologies and solder paste advancements. Additionally, she has appeared on podcasts discussing the development of new solder products.
Her extensive background in technical communication and her role at AIM Solder highlight her significant contributions to the electronics manufacturing industry, and today she’ll be sharing her insights from a recent technical article “What’s on Your Rework Bench.”

In this discussion, we’ll review the rework station and the essential practices that can make or break circuit reliability. Gayle will walk us through the common pitfalls she’s seen—from the dangers of unapproved fluxes to mismatched cleaning solvents—and explain how these mistakes lead to long-term failures in the field.

She’ll also share practical advice on maintaining a contamination-free bench, the importance of selecting compatible chemistries, and why regular audits and operator education are key to preventing unintended residues and contaminants.

Gayle will help us prevent one problem, rework, while not creating another, contamination.

Gayle’s Contact Information
Gayle Towell
gtowell@aimsolder.com
https://www.aimsolder.com

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An Introduction to Flexible Circuits with Joseph Fjelstad

On today’s episode, we’re turning our focus to a pivotal innovation that has transformed design and manufacturing processes: flexible circuits.

Flexible circuits have emerged as a game-changer in the manufacturing and design of electronic assemblies. With their unique ability to bend, twist, and conform to complex shapes, they offer unparalleled advantages in applications where space is at a premium and reliability is paramount.
From wearable technology and medical devices to aerospace systems and consumer electronics, the use of flexible circuits has expanded rapidly, bringing with it both opportunities and challenges.
In this episode, we’ll explore the evolution of flexible circuit technology, discussing its key benefits, such as lightweight construction, enhanced durability, and improved design freedom.

We’ll also touch on the manufacturing complexities, material considerations, and the critical role that process control plays in ensuring reliability and performance.

My guest today is Joseph Fjelstad. Joe is the founder of Verdant Electronics.
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Ultra HDI Panel Discussion – Recorded Live at SMTA!

Today, I’m in Rosemont Illinois at SMTAI, Surface Mount Technology International. I’m in the Ultra-HDI Pavilion on the trade show floor. And what are we going to talk about here in the Ultra-HDI pavilion? Ultra high density interconnects, of course.

As the demand for smaller, faster, and more powerful devices grows, the need for innovative solutions in circuit design has never been greater. UHDI’s represent a significant leap forward, allowing for more connections in a smaller space, pushing the boundaries of what’s possible in electronic assemblies.

But what exactly are UHDI’s? Essentially, they refer to circuit boards with incredibly fine pitch interconnects, enabling higher functionality and complexity in much smaller form factors.
This breakthrough is transforming industries like consumer electronics, aerospace, automotive, and medical devices, where space, weight, and performance are critical factors.

In this episode, we’ll explore the advantages UHDI’s bring to the table, from increased design flexibility and performance to better thermal management. We’ll also discuss how UHDI’s are set to impact the assembly process. With tighter tolerances and more intricate layouts, UHDI assemblies will require new approaches to assembly, inspection, and reliability testing.

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Thermal Profiling Best Practices

One of the most critical aspects of manufacturing high-reliability circuit assemblies is thermal profiling during the reflow process.

Whether you’re designing, engineering, or troubleshooting circuit assemblies, understanding how temperatures during the reflow process influences the quality and performance of your assemblies is essential.

In this episode, we’ll break down what thermal profiling is, why it’s important, and how it affects everything from solder joint integrity to component placement.

We’ll also explore the challenges and solutions involved in getting your thermal profile just right, ensuring your circuit assemblies are built to last in a competitive and demanding industry.
Will review thermal profiling best practices, common mistakes, and the various capabilities of thermal profilers.

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Contract Manufacturing Best Practices with Adrian Leal

If you’re part of the electronics landscape, you’ve likely encountered the role contract manufacturers play — and it’s a critical one. These specialized partners bridge the gap between design innovation and full-scale production, bringing efficiency, expertise, and flexibility to the table.

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High-Reliability Solder Paste Selection Best Practices

As the demand for more durable and dependable electronics continues to rise across industries, the choice of soldering materials, such as solder paste, plays a pivotal role in determining the reliability of these devices. We’ll discuss how selecting the right solder paste can influence performance and longevity, and we’ll hear from an industry expert about the latest advancements and best practices in soldering material technology.

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Optical Inspection System Best Practices

Two episodes ago, episode 149, we talked all about automated optical inspection. Today we’re exploring the impact of less automated inspection Technology, that being optical microscopes.
From commercial, class 1 electronics to high reliability class 3 electronics, the intricate electronic devices we rely on daily are assembled with astonishing precision. This precision wouldn’t be possible without the aid of advanced optical microscopes. These remarkable instruments allow technicians and engineers to inspect, analyze, and ensure the quality of electronic components down to the minutest detail.

In this episode, we’ll uncover how optical microscopes have impacted electronic assembly, enhancing productivity, ensuring reliability, and driving innovation.

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The Truth Behind Statistics

Statistics, at its core, is the science of making sense of data. From predicting trends and making informed decisions to ensuring quality control and optimizing processes, the applications of statistics are vast and varied. In the electronic assembly industry, where precision and reliability are paramount, statistical techniques become indispensable tools for engineers, manufacturers, and quality assurance professionals alike.

Join us as we unravel the complex yet captivating connections between statistics and the truth. We’ll delve into real-world case studies, and uncover the statistical principles that ensure the decisions we make every day are based on facts, accurate data, and accurate statistics.
In today’s episode, we’re also going to tackle some common myths associated with statistics and shed light on how misinterpretation of data can lead to false conclusions. Many people think of statistics as infallible, a definitive answer to every question posed by data. However, this couldn’t be further from the truth. Statistics is a powerful tool, but its effectiveness hinges on proper application and interpretation.

We’ll discuss myths such as “Correlation equals causation,” where the mere relationship between two variables is often mistaken for one causing the other. We’ll also address the misconception that a larger sample size always guarantees accurate results, and how ignoring the context or the source of data can lead to misleading outcomes.

Moreover, we’ll explore real-world examples where statistical missteps have led to costly errors and how these pitfalls can be avoided through rigorous analysis and critical thinking. By understanding these common misconceptions and learning how to approach data critically, you’ll be better equipped to harness the true power of statistics.

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AOI and X-Ray Best Practices

In today’s episode, we’re exploring automated optical inspection (AOI) and x-ray inspection technology within the electronic assembly industry.

Joining us are two experts who bring a wealth of knowledge and experience to the table.

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IPC Apex Special (part 3 of 3)

Recorded live in Anaheim California during the IPC Apex Expo.

This episode features four interviews including:
• Kimberly Fagan from PVA
• Taylor Wagan from CETEC ERP
• Neil Hubble from Akrometrix

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IPC Apex Special (part 2 of 3)

Recorded live in Anaheim California during the IPC Apex Expo.

This episode features four interviews including:
• David Chiu from Test Research, Inc.
• Michael Dolan from South-Tek
• Dalton Dodge from Brooks Automation
• Michelle Ogihara from Seka Machinery, Inc.

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IPC Apex Special (part 1 of 3)

This episode features three interviews including:
• Gus Mavrou from Seho
• Mark Stansfield from Solderstar
• Jesper Lykke from Viscom

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Designing Electronics to be Reliable in Harsh Environments

The challenging world of electronics becomes even more challenging when the end product is destined for harsh environments. For high reliability products operating in a harsh environment, the quest for reliability is not just a goal—it’s an imperative. These are not your everyday gadgets; often they’re critical components of systems designed to operate under extreme conditions, where failure is not an option. From the scorching heat of desert landscapes to the unyielding cold of arctic tundras, from the high-pressure depths of our oceans to the radiation-filled expanse of space, the demands on these electronic products are as varied as the environments themselves.

While ocean depths, outer space, and frozen tundras are arguably harsh environments, we don’t have to look too far for examples of product failures in less harsh environments. One example that comes to mind is the state of public EV charging stations. Government reports have concluded that up to 25% of public EV chargers are at any given time.

While there are many reasons for this, one may conclude they are not designed and manufactured for the intended in climactic operating environment.

On this episode, we’ll uncover the numerous challenges that designers and engineers face in their quest for reliability, durability, and functionality of the final product.

As we navigate through this complex landscape, we’ll highlight the strategies that enable these products to not just survive, but excel in unforgiving conditions.

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