Design for Manufacturability (DFM) ensures high-yield, low-cost PCB production by identifying issues
early in the design phase. Proper DFM practices reduce delays, minimize rework, and improve long-term
product reliability.
Why DFM Matters
The data tells the story:
- Up to 70% of manufacturing cost is determined during design.
- 50% of new product failures stem from manufacturability issues.
- 35–50% cost reduction is typical when DFM principles are applied early.
Investing time into DFM results in fewer revisions, shorter lead times, and a smoother production lifecycle.
Copper Spacing & Trace Rules
Minimum trace width and spacing depend on copper weight:
| Copper Weight |
Min Width |
Min Spacing |
| 1 oz |
4 mil |
4 mil |
| 2 oz |
6 mil |
6 mil |
Falling below these limits increases the chance of over-etching and broken traces. Maintain proper design
margins for reliability.
Via Design Rules
- Standard vias: 10 mil drill, 20 mil pad.
- Microvias: Required for HDI and fine-pitch components.
- Aspect ratio: 10:1 max for reliable plating.
- Avoid blind/buried vias unless necessary due to higher cost.
Annular Ring Requirements
- Minimum 4 mil annular ring for standard processes.
- 5+ mil recommended for high-yield production.
- High-current designs require larger rings.
Routing & Panelization
- Use 50 mil internal slot radius minimum.
- Slots requiring routing increase cost — avoid if possible.
- Panelization choices affect board strength and manufacturing efficiency.
DFM for SMT Assembly
Good component placement prevents assembly defects.
Placement Rules
- ≥ 50 mil spacing between components for reflow.
- 100 mil clearance for rework access.
- Align orientation across similar components.
- Follow manufacturer-recommended pad sizes.
Thermal Pads & Vias
- Use via arrays for thermal pads.
- Ensure solder mask coverage for via-in-pad.
- Balance thermal relief to prevent tombstoning.
Fiducials
- Global fiducials on opposite corners.
- 1 mm diameter typical.
- Keep 2 mm clearance from pads.
DFM Review Process
Every DFM review at Xekera includes:
- Automated rule analysis of your design files.
- DFM engineering review for high-risk features.
- Thermal, manufacturability, and assembly checks.
- A full report with revisions and recommendations.
This process typically completes within 24–48 hours and results in:
- Reduction of revision cycles by up to 60%.
- Lower manufacturing costs by 15–25%.
- Improved first-pass yields by 20%.
Ready to Start a DFM Review?
Submit your design files for a free review. Our engineering team will analyze manufacturability,
identify risks, and recommend optimizations.
Start your project with confidence — partner with Xekera today.