The Hidden Challenges in Manufacturing Variations

In this work we will examine the manufacturing variation effect and design robustness in the context of complex PCB structures’ performance for high-speed links. A case study of robust design implementation for a differential capacitor structure is examined. The main design parameters variation is identified and key contributors to performance degradation are outlined. Then a method of maximizing design robustness is presented and a commonly used design is altered to maximize immunity to manufacturing variation. The proposed structure robustness is analyzed, and superior impedance control under various scenarios of expected manufacturing variation is demonstrated.