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Designing and building next-generation electronic products is a complex process,
especially considering today’s highly competitive global industry where rapid and ongoing
technological change has become commonplace and innovation rules. Designers failing
to embrace these changes risk being left behind their competition or worse yet, unable
to compete at all. Nowhere is this trend more evident than when it comes to printed circuit
board (PCB) design. In this market space, the consumer’s desires for smaller, cheaper,
faster, and more functional electronic products, coupled with shrinking design cycles
and geographically dispersed design teams, is driving up design complexity and pushing
conventional design tools to their limits. Further adding to PCB complexity is the increasing
number of nets, stricter design constraints and wiring density, as well as ongoing migration
toward high-speed, high-density projects – trends which are affecting all sectors of the
industry, not just the high-end consumer electronics segment.
Luckily, PCB design tools have steadily evolved through the years to address the challenges
brought about by this increasingly complex design space. One key change – the introduction
of 3D capabilities – promises to revolutionize the way designers not only create their
designs, but compete in the global marketplace as well.
Keeping Pace with Industry Trends
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Challenges of Designing in a 3D World
Traditionally, circuit-board designers have relied on design mockups to ensure form,
fit and function prior to fabrication. While viable, this approach has a number of drawbacks
— not the least of which is that designers can’t be sure their circuit boards will fit until
an actual prototype is manufactured. Additionally, the use of mockups generally adds
multiple re-spins to the design process. Considering the time-consuming nature of re-spins,
and that for a design of only moderate complexity the average cost of re-spins is $8,929[i]
per spin, it’s easy to understand why this approach has become prohibitive. Adding any
extra time or expense to the design process not only makes a company less competitive,
but also makes it harder when trying to acquire new business.
Another drawback is that PCB design has traditionally been done in 2 dimensions.
Essentially, designs are created in 2D, marked up by hand, and then passed onto mechanical
designers who use mechanical CAD software to redraw designs in 3D. This approach is very
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Figure 1. With 3D visualization of a design, designers can examine all aspects of a design, inside and out, in 3D.
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Design of only moderate complexity the average cost of re-spins is $8,929.
time consuming, given its manual effort, and prone to errors. Moreover, it fails to deliver
the competitive differentiation needed to design next-generation electronic products. The
problem here is clear. Circuit board designers require a better way to visualize and analyze
their increasingly complex designs.
Given that the end goal for PCB designers is to create products for the real world (which
has 3 dimensions), the best way to answer this challenge is through use of a design tool
with advanced 3D capabilities. Having such capabilities allows designers to view realistic
3D images of their designs prior to fabrication, eliminating the need for mockups, as well
as design re-spins, and saving both time and money (Figure 1). Accurate 3D models
of objects can be easily generated and then used to create a layout of the board in true
3D. A 3D model of the design’s intended enclosure can also be included in the PCB design,
enabling the circuit board to be designed from scratch to fit within the enclosure.
As a result, designers can more confidently submit their design files for manufacturing.
The availability of 3D design export capabilities allows designers to conduct further design
analyses, such as thermal and electromagnetic simulation in multi-physics tools. These are
especially critical functions given that heat in the enclosure is dependent on the shape
of the board, and these days, almost every new compact battery-operated device uses
wireless connectivity. Because of such features, 3D capabilities in PCB design tools are now
absolutely essential for fast, accurate and cost-effective next-generation design.
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The value of 3D functionality in PCB design is undeniable and as a result, a number
of companies now claim to offer them; however, all 3D-enabled design tools are not
created equal. To reap the full benefits of 3D, it’s critical for designers to utilize a PCB
solution that goes well beyond the ability to view realistic 3D images to offer full 3D
functionality, including:
Full 3D PCB Design Capability
The ability to create 3D animation/video of a design. With this capability, designers can
easily share and sell their product designs, or even generate sales and marketing material.
It also enables better collaboration with an extended design team or manufacturer. With
a 3D video, for example, the designer can show the manufacturer what the product should
look like after it is assembled. The video might also be used to specify the order in which
parts should be placed on a board.
The ability to bring 3D modeled objects, in addition to components, into a circuit board
design. Note that some design tools stop short of this capability, only allowing the designer
to perform basic visualization and clearance checking from component to component
in 2D. However, it is equally important to be able to include enclosures and other
mechanical objects to get placement and layout right the first time.
3D functionality that’s actually in the design rule checker; a very important feature since
rules should serve as a real-time guide to the design process. A 3D modeling design rule
checker tells the designer whether interference will occur between two components
or enclosures and heat sinks, placed near one another in 3D space, on all axes.
The ability to model the copper layers within a laminated structure. Despite using an ECAD
package with 3D capabilities, design problems can still occur during manufacturing. Finding
an issue at this late date can be quite costly. Having the ability to model the structure’s
copper layers allows designers to easily view and verify connections to internal planes and
thermal reliefs.
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Figure 2. Altium Designer supports all aspects of next-generation electronic product development.
A prime example of a design tool with full 3D capability is Altium Designer. This single-
application unified electronic design environment caters to all aspects of the electronic
development process, from front-end design and capture and physical PCB design,
to signal integrity analysis and PCB manufacturing output generation at the back end
(Figure 2). The solution allows engineers – novice and expert alike – to move to a ‘soft
design’ methodology without having to acquire specialist expertise. Doing so enables
them to deliver more innovative designs in less time, while also being able to explore
design possibilities with a freedom and ease not possible with other commercially available
systems.
Altium Designer comprises the editors and software engines needed to perform all aspects
of the electronic product development process. All document editing, compiling and
processing is performed within the Altium Designer environment. Tying the various editors
and software engines into a single integrated environment is the Design Explorer (DXP)
Integration Platform. The DXP provides a consistent user-interface across all tools and
editors, as well as enhanced tool-interoperability, which enables users to smoothly and
easily switch between various design tasks. It is also responsible for providing a wide range
of features that are common across tools, saving multiple implementations of the same
features and speeding the development process.
The exact set of features and functionality available with the solution depends on the
specific license purchased. For added flexibility; however, it seamlessly interfaces to
supporting tools, such as FPGA vendor place and route software or third-party HDL
simulation and synthesis software. Altium Designer is also fully customizable, with
a powerful scripting system and API.
Productivity Calls for a Next Generation Design System
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As a PCB design tool with full 3D capability, Altium Designer offers all of the 3D
functionality previously discussed. With its native PCB editor, designers gain quick and
easy access to this functionality by simply switching from the tools’ 2D mode to 3D mode.
In contrast, other solutions require the user to open their designs in a separate program
or “viewer” to access 3D capabilities; a highly error-prone and limited process. When in 3D
mode, Altium Designer uses its 3D output to enable full 3D assembly model export, which
in turn allows for easy generation of corresponding 2D assembly drawings and associated
manufacturing documentation.
With Altium Designer’s 3D Visualization Panel, up to three simultaneous 3D cross-sectional
views of a design can be viewed at one time. These views allow designers to examine all
aspects of their design while still working on it in either 2D or 3D mode. Altium Designer
also provides a set of predefined views and real-time camera movement for designers
working in the 3D mode. These views replicate the designer’s ability to turn and rotate
a physical board in the real world. Additionally, PCB 3D Orthographic Projection allows
designers to view precise object geometry, including exact positioning of components and
details that might ordinarily be hidden from view. The result is an even more realistic view
of the board and an enhanced ability to edit design data.
A key differentiator of Altium Designer is its reliance on the compute power and
performance of mainstream hardware. Most design tools with 3D capabilities require the
user to buy expensive hardware and utilize OpenGL for hardware acceleration. Altium
Designer; however, leverages modern gaming hardware cards and DirectX to allow
designers to access the same level of performance on a standard computer. As a result,
its 3D capabilities are available to everyone, not just those able to afford the added expense
of costly workstations.
Some of the key 3D capabilities offered by Altium Designer include:
A Closer Look Under The Hood
STEP Import/Export. With this feature, users can easily export to STEP for
interoperability with mechanical tools for clearance checking or thermal analysis.
This feature is also helpful when assembly of multiple circuit boards is required. In this
case, 3D models of each of the boards can be created, imported as STEP files to create
3D components and then fitted together – right within the workspace.
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Figure 3. 3D bodies are used to define the physical size and shape of a component, both in the horizontal and vertical planes, which enables more precise and controlled component clearance checking by Altium Designer’s Design Rule Checker.
Note that Altium Designer can also create general 3D bodies without having to use
a separate CAD program (Figure 3). A 3D body is a primitive polygon type design
object that can be placed into a library component footprint or PCB document, on any
enabled mechanical layer. 3D bodies can be used in 2D and 3D mode. In 3D mode,
they are used to render an extruded 3D shape for a component or object. In 2D mode
their outlines can be used for detailed assembly drawings.
The 3D body object acts as a placeholder for embedded or linked 3D STEP model
files. The ability to handle STEP file imports in this manner improves ECAD-MCAD
compatibility by making it possible for mechanical models representing non-board
mounted, free-floating design objects (e.g., housings or enclosures) to be brought into
Altium Designer and accurately assembled in the 3D workspace. As a result, designers
can visually and accurately verify designs, including clearance checking between all
types of 3D bodies, directly within the Altium Designer environment.
Whether created in Altium Designer or imported as a STEP file, the 3D objects
or components can be saved within the tool’s library for use on future design projects.
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7
Figure 4. With Altium Designer’s PCB 3D video capability designers can essentially produce their own 3D movies.
Figure 5. Real-Time Clearance Checking and Collision Detection dramatically reduce the amount of time taken for accurate placement and number of board spins.
3D Movie Generation. Altium Designer easily generates 3D video documentation
of a given board design (Figure 4). The video’s content consists of a sequential set
of snapshots of the board in 3D. For each snapshot in the sequence, designers are
free to adjust zoom-level, pan and rotation, directly in the workspace, relative to the
settings for the previous snapshot. This 3D video capability has a number of critical
uses, including for design reviews, specification of angles at different time steps, and
zooming in on different customer specifications.
3D Clearance Checking. This feature enables imported enclosure models to be included
in the design process (Figure 5). With these models, users can ensure a desired circuit
board layout will fit correctly within the intended enclosure the first time.
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Figure 6. With 3D Visualization of the copper, nets, net classes and objects associated with Design Rule Errors are highlighted in 3D, making it much easier to physically see the problem and come to resolution.
3D Visualization of Electrical Design Rule Violations in Copper. This feature allows
designers to model the copper layers within a laminate structure for the purposes
of viewing and verifying its connections and checking for any design rule violations.
When problems are found in the copper, they are highlighted in 3D (Figure 6), allowing
the designer to zoom in and see the problems, which otherwise would not be found
until product manufacturing occurs.
3D Awareness of Variance. With this feature, all 3D models have a built-in awareness
of design variants, so 3D videos, exported STEP models, and assembly documentation
reflect the selected configuration of the board assembly.
3D Sectional Views. This feature allows the user to view 3D cross sections within
a design. When viewing assembly drawings with 3D models, the user simply positions
the mouse at the particular part of the design that they want to view in greater detail.
A 3D cross section of the section of the design automatically appears.
3D Visualization, including videos, can be used to significantly improve the design
review process.
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9
Reducing the PCB Design Time by Eliminating Uncertainty.
Designing in 3D brings with it a host of key benefits. It shortens the design cycle by reducing
iterative MCAD-ECAD loops to one (or in some cases, zero) and minimizes design errors,
in turn dramatically increasing productivity. And, by eliminating the uncertainty over
whether or not the board layout will fit in the enclosure, designers are freed up to focus
their attention on making the product more aesthetically pleasing.
Other important benefits of designing in 3D include:
A competitive edge over the competition. Designing in 3D speeds product design,
streamlines manufacturing and accelerates product introductions by improving
communication throughout an organization, as well as among its suppliers and
customers. The faster time-to-market and higher quality products translate into
increased revenue, while reduced design costs provide larger profit margins.
Improved global collaboration. A realistic, 3D image of the design enables more
effective communication with suppliers/customers and manufacturers. It even allows
non-CAD people to participate in the process (e.g., by providing a customer quote
and specifying or configuring the product). This is especially critical given that many
companies are now opting to manufacture offsite, either in China or locally. The global
nature of the design / manufacturing process leaves the door wide open to errors and
misunderstandings regarding the design intent or desired end product. A 3D image of
the design provides the common, easily understood framework from which all team
members can operate.
More efficient design reviews/modifications. The ability to create 3D renderings and
animations simplify design proposals and reviews among members of a design team.
It also allows designers to easily make modifications and incorporate late design
changes. Once a modification / change has been made, for example, a new 3D
rendering or animation can be generated as proof.
More efficient manufacturing/assembly process. 3D models provide a common basis
from which manufacturers can work, while also accurately and clearly communicating
design intent and pertinent design detail. They also ensure errors that typically would
not have been found until manufacture are now found early in the design process.
As a result, the manufacture / assembly of a product using a 3D model is much more
accurate and efficient.
Improved sales and marketing. 3D models of products serve as a valuable marketing
tool and can even help create additional revenue by allowing customers to see their
product prior to manufacture and enabling the sales department to quickly quote
products.
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10
Conclusion
Over the years, real-time 3D graphics have revolutionized the way society interacts with
computers. With 3D PCB design tools, that revolution has now come to the PCB design desktop.
In doing so, it is changing the way electronic products are designed and manufactured. As with
any new technology or approach; however, finding the most optimal way to implement and use
it is essential. For PCB designers wanting to reap the benefits of 3D, that means selecting
a software solution offering full 3D capabilities. Use of this type of solution promises to provide
today’s circuit board designers with the functionality they need to create highly competitive,
next–generation electronic products in an increasing complex design environment.
About Altium: Altium Limited (ASX:ALU) provides world-leading unified design solutions that break down the barriers
to innovation, and help organisations easily harness the latest devices and technologies, to create their next generation
of electronic products. Founded in 1985, Altium has headquarters in Shanghai, China, sales offices in the United States,
Europe, Australia, and resellers in all other major markets.
For more information, please visit www.altium.com
[i] Boucher, M. “Why Printed Circuit Board Design Matters to the Executive: How PCBs Are a Strategic Asset for Cost Reduction and Faster Time-to-Market” (2010 Aberdeen Group Case Study, p8)
More details available online at: http://altium.com/en/solutions/ecad-meets-mcad
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