At Kejie PCB, we manufacture and deliver high-quality printed circuit boards (PCBs) every day — and over the years, we’ve seen how small design issues can cause big problems during production. Even the most skilled engineers sometimes overlook critical details that impact reliability, manufacturability, and cost.
Here are five common PCB design mistakes we still encounter — and how you can avoid them to ensure a smooth production process:
1. Poor Ground Plane Continuity
A continuous and solid ground plane is essential for maintaining signal integrity and minimizing electromagnetic interference (EMI). Interruptions or splits in the ground plane can create noise issues and affect the overall performance of your board.
Tip: Always aim for a single, uninterrupted ground plane. If a split is necessary, carefully manage return paths and avoid sharp discontinuities.
2. Vias Too Close to SMD Pads
Placing vias too close to surface-mount device (SMD) pads can cause manufacturing defects such as solder wicking or voids during reflow soldering. This can result in poor mechanical connections and unreliable operation.
Tip: Maintain adequate clearance between vias and SMD pads. Follow your PCB manufacturer’s design for manufacturability (DFM) guidelines for proper spacing.
3. Sharp 90° Trace Angles
Sharp 90-degree angles in PCB traces can cause issues like acid traps during etching, which may lead to weaker traces and potential failure points. They can also affect signal integrity at high frequencies.
Tip: Use two 45-degree bends instead of a single 90-degree turn, or better yet, curve the trace gently to improve current flow and manufacturability.
4. Bad Decoupling Capacitor Placement
Incorrect placement of decoupling capacitors — especially too far from the power pins they are meant to stabilize — reduces their effectiveness and can lead to noise and performance problems.
Tip: Place decoupling capacitors as close as possible to the power pins of ICs. Minimize the length and impedance of the connection traces.
5. Ignoring DFM Guidelines
Design for Manufacturability (DFM) is critical to ensure your board can be produced efficiently, reliably, and at a reasonable cost. Ignoring DFM rules can result in production delays, higher costs, and increased risk of defects.
Tip: Always collaborate with your PCB manufacturer early in the design process. At Kejie PCB, we provide detailed DFM feedback to help you optimize your design for the best manufacturing outcome.
Conclusion
By addressing these common mistakes during the design phase, you can drastically improve the quality and reliability of your PCB projects — and avoid costly rework or delays.
Get Your PCB Designs Manufactured Right the First Time
Use this quick checklist before finalizing your next PCB design:
✅ Ensure ground planes are continuous and uninterrupted
✅ Keep vias at a safe distance from SMD pads
✅ Avoid sharp 90° angles in PCB traces
✅ Place decoupling capacitors close to IC power pins
✅ Always follow DFM (Design for Manufacturability) guidelines
At Kejie PCB, we specialize in high-quality, custom PCB manufacturing with strict adherence to DFM best practices. Whether you have a finalized design or need help refining it, our experienced team is here to ensure your production is smooth and efficient.
👉 Request a free quote or contact us today to start your next project with confidence!
