Medical device PCB manufacturing

Medical device PCB manufacturing in GWT

As medical technology has become more computerized, many diagnostic and treatment practices have come to depend on PCB board that require small, higher-density circuits to pack a larger number of connections into a tiny area along with other high-technology features that help make the products reliable and accurate.

The medical industry demands the highest standards of quality, precision, and reliability when it comes to their circuit board needs.Our engineering and production teams have expertise in all aspects of medical device PCB manufacturing, including an intimate knowledge of the IPC Class II and IPC Class III specification and HALT/HASS testing. We provide robust PCB solutions that exceed all the specific requirements of a medical device to ensure that our customers can get UL, FDA, IEC, and other necessary approvals. 

If you’re interested in PCB board for the medical industry, find out more about their main challenges and applications. Also, learn more about the core factors you’ll need to consider when designing medical grade PCB board and how we can help you.

Challenges of medical device PCB manufacturing

PCB board for the medical industry must meet a few different requirements to ensure they’ll deliver the performance required. A few of the main challenges a PCB provider must be aware of when sourcing medical PCB involve ensuring their PCBs meet compliance, size and reliability standards. Review some more information about the primary challenges PCB manufacturers must address with their PCB below:

1.Compliance: One challenge for companies looking for medical devices is that they need to work with PCB manufacturers who can manufacture to Class 3 electronic requirements. Since medical devices and equipment fall under this class, a company with expertise in producing Class 3 electronics will be more likely to produce PCBs meeting compliance standards. PCB manufacturers must also keep detailed records, with lot tracking being especially important. Medical industry PCBs must also adhere to installation qualification, operation qualification and process qualification standards.

2.Reliability: Since medical equipment outfitted with PCBs is often used for lifesaving purposes, they need to be reliable. Medical devices and the PCB boards in them are often exposed to extreme temperature, liquid and shocks. Due to this possible exposure, medical device PCB boards must be able to work in potentially dangerous environments and deliver reliable results.

3.Size: Due to the trend of companies wanting smaller and smaller electronics, medical industry PCBs often have to have a miniature construction to fit in smaller medical devices. A good PCB provider will know how to properly craft tinier PCBs that still provide top-tier performance.

Factors to consider when designing medical grade PCB board

As you look for the right PCB materials and specifications for your medical equipment and devices, you’ll have many different options to consider. By selecting the right PCB specifications for your medical device, you can receive the best performance possible. Check out some of the main PCB used in the medical field and some of the top factors that make particular PCB boards a good choice for certain applications below:

Flexible PCBs: Flex PCBs are a top choice for many medical devices. Since medical devices are often placed in locations requiring flexibility, the malleable nature of flex PCBs makes them a great option. When a medical device will be folded and wrapped, turn to flex PCBs.

Flexible aluminum PCBs: While flex PBCs are appropriate for many electronic medical devices, some high-power devices need a more powerful PCB. Flexible aluminum PCBs are perfect for high-power applications as they feature heat transfer qualities. Some top applications for these boards include scanning and surgical lighting applications.

PCB microcircuits: Another factor you might want to consider is whether you want to utilize flexible PCB microcircuits. Like flex PCBs, PCB microcircuits are malleable, but they separate themselves by allowing you to utilize even smaller PCBs with greater performance. Due to their design, PCB microcircuits are often used in small medical devices, such as industrial sensors, wearable technology and hearing aids.

Polyimide PCB material: As you look for the right base material for your PCB, polyimide is often a great choice. Polyimide PCB materials feature excellent tensile strength and flexibility. These materials are also highly durable, very thermally stable and chemically resistant, making them perfect for some medical devices, such as prosthetics and implants.

Ceramic PCBs:Ceramic PBCs are a great choice for organizations using medical devices with circuits featuring a low coefficient of thermal expansion and high thermal conductivity. These PCBs can operate in extremely high temperatures, provide incredible high-frequency performance, easily implement high-density tracing and offer tough chemical erosion resistance.

Rigid-flex PCBs: A rigid-flex PCB combines the benefits of flex circuits with the durability of rigid PCBs. The flexible materials sit in between rigid layers with conductors and are plated through holes to link them with other layers. These boards offer more durability than flex boards without the weight and size of rigid boards, presenting more design versatility. They’re common in applications like consumer electronics, lighting, contract manufacturing, instrumentation and more.

Medical PCB board Technologies

As the technology of medical devices continues to advance, we see the PCBs containing one or more of the following PCB technologies:

--IPC Class III:

The biggest issue here is reliability as the 3 biggest factors of the specification.

1.The PCB can have no annular ring breakout.

2.It must have a minimum of 1 mil of plating in the though holes.

3.Tighter tolerances on conductor spacing and widths.

--HDI / Via-in-Pad:

This technology allows us to reduce the footprint of the PCB.

--5 mil Lines and Spaces and Below:

This requires that the PCB fabricator has invested in equipment such as laser direct imaging so that the fabricator can get the production yield that is required as IPC Class III requires that there is very little reduction in the line width during processing.

--Experience with Many Different Laminate Types:

While FR-4 is the most common PCB laminate many medical devices require expertise in polyimide, Teflon, ceramic, and other materials in order to meet their unique requirements.

--Free PCB DFM Services:

This is critical to do even before any prototypes are made; if any major design for manufacturing changes need to be made, it can send you back to the drawing board. Remember, many unique features can be done in small quantities but are almost impossible to produce reliably in production.

Choosing the Right PCB Manufacturer

Working with your PCB fabricator, who is experienced in PCBs used in medical devices, is your best defense against project delays. Little things like circuitry directions, added copper thieving to ensure flatness, and internal layer recommendations are the types of things that PCB manufacturers like GWT know and that many electrical engineers haven’t yet experienced. Our job is to ensure the health of the public, and we take this responsibility very seriously.