PCB Design in the Medical Industry: Our Best Rules

Printed circuit boards, or PCBs, are super important in today’s healthcare world. They power all kinds of medical tools, from tiny wearable trackers to big fancy imaging machines. Thanks to huge steps forward in electronics, we now have medical gadgets with really cool features. Think of things like pacemakers, defibrillators, and heart monitors for heart problems, as well as imaging tools like MRI, CT, and ultrasound machines. Plus, there are tons of small, easy-to-carry, and wearable options. These devices need PCBs that are not just small and powerful but also super safe and dependable to meet tough standards.

Technologies for Medical PCBs

As medical gadgets get tinier and trickier to make, PCB tech has to keep up with these tough demands. One awesome solution is high-density interconnect boards, or HDI. These let us pack more parts into a smaller space, which is a big deal for today’s medical designs.

Flexible and rigid-flex PCBs are also pretty popular because they can bend and fit into odd shapes. Made from light stuff, flexible PCBs cut down the weight of the device. They help designers use space wisely without losing any strength or quality.

SMD and PTH Components

In most medical electronics, Surface Mount Technology, or SMT, wins over Plated Through-Hole, known as PTH. SMT is often the better pick for medical uses since it works with tiny parts. This shrinks the PCB size and fits more pieces on it. Also, SMT doesn’t need holes drilled into the board, making it simpler and cheaper to build.

Still, PTH has its place, especially for power areas or when connectors need extra toughness. The smallest SMD packages, like 008004 (0.25mm x 0.125mm), show how incredibly small modern parts can be.

Materials

Choosing the right stuff to make PCBs is a big deal because of strict rules and high expectations for how they should work. Since medical devices are so critical, picking the best materials is extra important. For regular use, FR-4 is common, but for high-speed or hot conditions, fancier options like polyimide or PTFE step in.

The FR-4 material has a dielectric constant of around 4.5, which can be too much for some needs. On the other hand, materials like Teflon have a lower value, around 3.5 or less. This is key for circuits that must avoid losing signals.

HDI boards often use via-in-pad tricks to make routing super efficient. This tech helps shrink PCB size a lot by using laser-made via-holes, via-in-pad setups, and super thin tracks, just 5 mil wide and spaced.

Longevity

Longevity isn’t just about how tough something is. It also means planning for how long parts will be around. When designing a medical PCB, it’s smart to think ahead about parts becoming outdated. Designers should team up with suppliers to pick pieces that’ll stay available for the whole life of the product.

If an important part goes out of stock too soon, it might mean starting over with approvals. That’s a pricey and slow process that could delay getting the product out by months.

Maintainability

Making things easy to fix should be part of every design step. Each stage of PCB planning should focus on simple assembly and upkeep. Connectors need to be easy to reach. Parts should be grouped in a way that makes sense. Tall bits should stay away from short ones to keep the board’s height even.

Building a 3D model while designing helps spot space issues inside cases. This model lets designers see the real size of the board and gives handy tips for putting it together.

Test and Debug

Testing is a must to make sure everything works before it’s used. The whole board should be set up to make testing and fixing easy. Test points ought to be placed smartly on power lines, clock signals, and other key spots. It’s best if these are on outer layers for quick access after everything’s put together.

Having a few extra test points is way better than missing them in important spots during checks or repairs out in the field.

Simulation

Simulation tools help catch design mistakes early, before making a real model. Methods like Digital Twin cut down on both cost and time to get a product ready. Thermal checks spot hot areas under different loads, so designers can fix things ahead of time instead of after pricey tests.

Digital Twin setups copy real-life actions based on inputs, letting engineers track how things work over time.

FAQ

Q1: What makes HDI PCBs suitable for medical applications?
HDI cuts down the PCB size while giving more room for routing traces. This makes it perfect for small designs that need lots of features, which is common in medical tools.

Q2: Why are flexible PCBs commonly used in wearables?
Flexible PCBs have big pluses over rigid ones, especially for wearables. They mold to weird shapes easily and weigh less.

Q3: What materials are best suited for RF-based medical devices?
Stuff like PTFE or Teflon, with low dielectric constants, is the top choice since they keep signal loss low at high speeds.

Q4: How do you ensure component availability throughout product life?
Team up closely with suppliers during planning to pick parts with long lifecycles or backup sources.

Q5: What simulation tools are beneficial during design?
Digital Twin setups mimic real-world actions, while thermal checks catch overheating risks early.

get your medical PCB manufacturing and assembly quote from PCBAStore in just a few clicks

PCBAStore gives you full Turn-Key and partial Turn-Key Circuit Board Assembly Services. With over 16 years in making boards and 8 years in assembly, they offer complete solutions made just for fields like healthcare.

We’ve got top-notch skills for SMT assembly, through-hole, and mixed tech PCB setups. This lets us handle all your PCBA needs in one spot at a low cost.

Their quick online quote tool lets you upload files straight to their site. There’s no minimum order needed, and you get price guesses in just minutes.

Online quote over 95% accurate

8H Expedited Delivery

Turnkey BOM Sourcing

10PCS Assembly starts at $100

Whether you’re testing diagnostic gear or ramping up making wearable health trackers, PCBAStore offers trusty help from idea to delivery, all in one place.