Pick, Place, Podcast

CircuitHub and Worthington

The Pick, Place, Podcast is a show where we talk about electronics manufacturing and everything related to getting a circuit board into the world. Join hosts Chris Denney from Worthington and Melissa Hough from CircuitHub as they discuss the pcb assembly process, design tips that will make your manufacturer love you, and talk to industry guests.

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21 episodes
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English

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Monday · 34 min
To BGA or Not to BGA
In this episode, Chris and Melissa tackle a listener question: When you have the choice between a BGA (Ball Grid Array) and a QFP (Quad Flat Package), which one should you choose? Chris breaks down the manufacturing pros and cons of each package, explaining why those intimidating hidden solder balls might actually be easier to work with than exposed leads. Using an STM32 microcontroller as an example, they explore how component pitch, PCB routing, via-in-pad requirements, and stencil design can affect manufacturing complexity, yield, and cost. Plus, why choosing the smallest possible package isn't always the best decision. They also catch up on some exciting developments at CircuitHub and Worthington, brainstorm a potential "Good, Bad, and Ugly" PCB design giveaway, and, in place of the usual pet peeve, Chris shares a strangely spicy observation about something you seem to find in every tourist town. Once you notice it, you might never look at vacation shopping the same way again! pickplacepodcast.com
August 10 · 1 hr 15 min
Building the factory of the future with CircuitHub CEO, Andrew Seddon
In this episode we are joined by CircuitHub co-founder Andrew Seddon for a conversation about the origins of CircuitHub and the future of high-mix electronics manufacturing. Andrew shares how his experience as a design engineer—and his frustrations getting increasingly complex hardware projects manufactured—eventually led to the idea behind CircuitHub. They revisit the company’s early days, including its original shared parts library, the first CircuitHub manufacturing order, and how Andrew and Chris first connected. The conversation then turns to the challenges of high-mix manufacturing and why seemingly simple ideas, like standardizing component libraries, become much more complicated in the real world. Andrew explains how those lessons ultimately led CircuitHub to rethink the manufacturing process from first principles and develop The Grid, which he describes as a “factory-scale robot” for electronics assembly. We also discuss the role of automation, the limitations of traditional manufacturing equipment and software, and why keeping manufacturing capabilities close to hardware designers matters for innovation. In this episode: A quick recap of the Boston Hardware Meetup and live DFM reviews The current surge in manufacturing demand Andrew’s background and the origins of CircuitHub CircuitHub’s first manufacturing order The complexity of high-mix, low-volume manufacturing Why standardized component libraries only get you so far The evolution and philosophy behind The Grid Building a “factory-scale robot” from first principles Automation and the future of local manufacturing Andrew’s pet peeve: slow walkers pickplacepodcast.com
June 30 · 31 min
Flex & Rigid-Flex PCB Assembly
Flexible PCBs can solve some incredible mechanical design challenges—but they also introduce a whole new set of manufacturing considerations. In this episode, we answer a listener's question about flex and rigid-flex circuit assembly, covering what actually changes on the manufacturing floor when a board bends instead of staying rigid. Chris shares lessons learned from developing Worthington and CircuitHub's flex PCB assembly process, including the custom fixtures, dummy boards, baking requirements, and reflow considerations that make these jobs very different from traditional FR-4 assemblies. If you're designing a flex or rigid-flex PCB—or thinking about it—this episode offers practical advice that can save both time and money before your design reaches manufacturing. f you're designing flex or rigid-flex PCBs, Chris recommends these Global Electronics Association resources: IPC-2223: Sectional Design Standard for Flexible/Rigid-Flexible Printed Boards – The primary design standard for flex and rigid-flex PCBs. Covers bend regions, stackups, conductor routing, fabrication drawings, ZIF connectors, dielectric thicknesses, and many other design considerations. Used alongside IPC-2221. https://shop.electronics.org/ipc-2223/ipc-2223-standard-only IPC PCB Design for Flex & Rigid-Flex Boards Course – An in-depth instructor-led training course covering flex PCB design, manufacturing, assembly, documentation, and industry best practices. https://www.electronicsu.org/product/pcb-design-flex-rigid-flex-boards pickplacepodcast.com
June 1 · 36 min
Gloves not Mittens
In this episode Chris and Melissa dig into one of Chris’s favorite PCB design topics: pocket masking vs. gang masking on fine-pitch components. Chris explains why solder mask slivers matter, how PCB design tools can accidentally create manufacturability problems, and what designers can do to help prevent solder bridging during assembly. The discussion covers solder mask expansion, registration tolerances, stencil printing, pick-and-place placement pressure, and why “gloves, not mittens” is the mental model to remember. The episode also opens with a few updates, including Chris becoming a Certified Electronics Program Manager and CircuitHub announcing a $28 million raise from Plural Ventures. TL;DR: For fine-pitch components, especially 0.5 mm pitch and smaller, pay close attention to your solder mask expansion. Chris’s rule of thumb: Start checking at 0.5 mm pitch or smaller Aim for 10 mil spacing between copper pads, edge-to-edge Reserve 3 mil for solder mask registration on each side Preserve a 4 mil solder mask sliver between pads In metric, that means roughly: 0.25 mm copper-to-copper spacing 0.075 mm registration allowance on each side 0.1 mm solder mask sliver If space is tight, Chris recommends trimming the copper lands slightly rather than sacrificing the solder mask sliver. The sliver is what helps prevent solder from bridging between pads during printing, placement, and reflow. The short version: protect the solder mask sliver. Gloves, not mittens. pickplacepodcast.com
May 4 · 50 min
Back from the Dead and Back from APEX
In this episode, Chris and Melissa return after a long break with a recap of Chris’s trip to APEX. They discuss customer visits, EMS management meetings, the value of trade shows, and why x-ray inspection is becoming such a big topic in PCB assembly. Chris also talks about AI, reusable checklists, his new Feeder Pugs project, and the time a hotel accidentally drilled into his room. Melissa closes things out with a pet peeve about signs that block traffic visibility. pickplacepodcast.com
Oct 6, 2025 · 1 hr 20 min
Smarter Test Plans for Inevitable Failures w/ Blue Clover CEO & Co-founder, Pete Staples
Chris and Melissa welcome Pete Staples, CEO & co-founder of Blue Clover Devices, for a deep dive into how to plan tests, capture evidence, and debug those mysterious boards that look perfect but don’t work. Topics include: Who is Blue Clover Devices & what’s the PLT? Bed-of-nails, ICT, flying probe, and PLT What assemblers really need when a board fails Production test vs. validation Updates on the Stick It Up Your Tube movement Ben the Beaver Links & resources Blue Clover Devices — Production Line Tool (PLT). Blue Clover Devices PLT Reference Docs (test plans, reports, hardware reference). docs.pltcloud.com+1 Blue Clover — Design-for-Test (DFT) Guide (request the PDF). Blue Clover Devices pickplacepodcast.com
Aug 25, 2025 · 50 min
Inevitable Failures
After a long break (and a few listener wellness checks!), Chris and Melissa return to catch up on what’s kept them busy and share some updates from around the industry. Then, they dive into this episode’s big topic: who’s responsible for the inevitable fallout when it comes to quick-turn PCB assembly? Topics include: Catching up after six months of growth, hiring, and training Andrew Seddon’s appearance on The Amp Hour — and how it ties back to the origins of this podcast IPC’s rebrand to the Global Electronics Association The ongoing saga of stuck parts in tubes (a.k.a. “Stick It Up Your Tube”) Quick-turn fallout: Why some customers expect and accept a small percentage of failures Why others demand 100% working boards How assembly shops handle each scenario (good, bad, and ugly approaches) Practical tips for managing fallout: thermal cycling, batch troubleshooting, and respectful customer–assembler relationships Pet Peeve of the Week: LinkedIn (and why it feels so weird) Links & Resources Andrew Seddon on The Amp Hour: CircuitHub 12 Years Later IPC rebrand: Global Electronics Association announcement LinkedIn post – stuck part in a tube LinkedIn post – sustainability rant pickplacepodcast.com
Mar 1, 2025 · 2 min
Meet up with Chris in California!
Chris will be in California and would love to meet up with anyone interested. He will be in the San Francisco Bay Area March 11 - March 14 and the Los Angeles/Anaheim area March 16 - March 20. Email us at contact@pickplacepodcast.com and we'll try to make something happen! pickplacepodcast.com
Feb 17, 2025 · 1 hr 10 min
IPC's Leadership on Sustainability in Electronics w/ Dr. John W. Mitchell and Dr. Kelly Scanlon
In this insightful episode, we delve deep into the pressing issues of sustainability within the electronics manufacturing industry with IPC President and CEO, Dr. John W. Mitchell, and Dr. Kelly Scanlon, IPC's lead sustainability strategist. They offer expert insights into how IPC is leading the charge toward more sustainable practices, the importance of data and harmonization in policy-making, and the challenges facing the industry today. Our discussion also highlights practical steps manufacturers can take to contribute to a greener future and how IPC's resources can guide these efforts. If you're interested in learning more about sustainability or getting involved with IPC's initiatives can visit IPC.org for further information and support. pickplacepodcast.com
Jan 27, 2025 · 1 hr 2 min
Innovations in Motorsport Sensor Technology with Caleb Holloway of Izze Racing
In this episode, join us as we continue our exploration into the high-speed world of motorsport sensor technology with Caleb Holloway, founder of Izze Racing. Caleb delves into the complexities of antenna design, the challenges of RF engineering in the demanding environment of racing, and the innovative solutions his team has developed to enhance data accuracy on the track. From whip antennas to the nuances of sensor integration on racing vehicles, learn how cutting-edge technology is driving performance and safety in motorsports. pickplacepodcast.com
Jan 13, 2025 · 43 min
The Challenges of Motorsport Sensor Design with Izze Racing Founder, Caleb Holloway
After a bit of a break we are back with a new, exciting episode! This week we are joined by Caleb Holloway, founder and owner of Izze Racing. Izze Racing provides electronics sensors, with an emphasis on tire data collection, to the motorsport industry. In the first part of this conversation, we delve into Caleb's transition from academia to running his passion company full-time, what's it like designing a product for the motor racing industry, and some unique challenges he has faced. pickplacepodcast.com
Nov 4, 2024 · 34 min
Mastering Vias: Plugging, Filling, and Best Practices
In this episode, we continue our conversation from last episode with Dave Wilcox, PCB CAM engineer at CircuitHub, to explore the intricacies of plugging and filling vias. Topics Covered: The differences between plugging and filling vias, and when to use each method. The common challenges faced during the reflow process, including the infamous "popcorn effect" caused by trapped flux. Practical advice on preventing manufacturing issues related to via plugging. Cost considerations between tenting, plugging, and filling vias. Insights into using various materials for via filling, including epoxy and solder. A fascinating case study on using solder to plug vias for gas sensors. The importance of thoughtful PCB design and silkscreen placement to avoid manufacturing headaches. Key Takeaways: Plugging vias can prevent air and flux entrapment, but must be carefully specified in the design. There’s a delicate balance between cost and functionality when choosing how to handle vias. Thoughtful design and clear communication with manufacturers can lead to smoother production and better results. pickplacepodcast.com
Oct 21, 2024 · 24 min
Vias, Tenting, and Tiny Fireworks
In this episode, Chris and Melissa we are focused on the topic of tenting vias. Joined by our favorite PCB guru, Dave Wilcox, we dive into the thrilling question: is it "via" or "v-eye-a"? We discuss the technical details behind different types of vias, tenting methods, and the potential manufacturing challenges that arise from improper designs such as why covering one side of a via might just lead to a tiny PCB firework show. Make sure to look out for part 2 of this episode where we continue on to learn about plugging and filling vias. Reference Links https://resources.altium.com/p/IPC-vias https://www.wellpcb.com/blog/pcb-manufacturing/non-conductive/ pickplacepodcast.com
Oct 7, 2024 · 54 min
Navigating the Environmental Impact of Electronics w/ Component Sense Founder, Kenny McGee
In this episode, Chris and Melissa continue their conversation with Kenny McGee, founder of Component Sense. We explore the environmental impact of electronics manufacturing and discuss how companies like Component Sense work to redistribute unused parts, reducing waste in the industry. Kenny shares insights on sustainability challenges for small businesses, his personal passion for reducing waste, and the global issues around recycling and electronic component reuse. pickplacepodcast.com
Sep 23, 2024 · 45 min
How Component Sense helps components fulfill their destiny w/ Kenny McGee
In this episode Chris and Melissa sit down with Kenny McGee, founder of Component Sense, to dive into the intricacies of the electronics supply chain. Kenny shares his journey from working in electronics manufacturing to founding Component Sense, a company focused on capital recovery from excess inventory while promoting sustainability. Tune in to learn about the environmental impact of excess electronic components, the importance of redistributing stock, and the challenges of reducing waste in the industry. pickplacepodcast.com
Sep 2, 2024 · 24 min
The RGB LED Dilemma in Manufacturing
In this episode of the PickPlace Podcast, Chris and Melissa discuss the challenges and intricacies of working with RGB LEDs, specifically the popular surface-mount DotStar LEDs from Adafruit. They dive into issues like handling cut strips versus continuous reels, the importance of sourcing directly from original manufacturers, and the need for moisture control when using these components in manufacturing. They also provide practical tips for engineers on cost-saving and quality assurance strategies when sourcing these parts for large-scale production. Show Links: https://www.adafruit.com/product/2343 https://www.lcsc.com/product-detail/RGB-LEDs-Built-in-IC_OPSCO-Optoelectronics-SK9822-A_C5378730.html https://docs.circuithub.com/en/articles/3350195-consigning-cut-strips https://www.digikey.com/en/products/detail/adafruit-industries-llc/2343/5761204 http://www.normandled.com/product/view/id/876.html pickplacepodcast.com
Aug 12, 2024 · 35 min
RF Shields and Restroom Rants
In this episode we delve into the topic of RF (Radio Frequency) shields. . Chris explains the different types of RF shields—open top, closed top, and clip-based—detailing their applications, advantages, and challenges. We also explore the processes involved in placing these shields on circuit boards, emphasizing the importance of inspection and the complexities of manual versus automated methods, and discuss how to choose the best type of shields for your project. More importantly, Chris shares a detailed story about a poorly designed bathroom he recently experienced and realizes that one of his big pet peeves is thoughtlessness. Show Links: Two Piece Shield Snap on, top piece: BMI-S-201-C https://www.digikey.com/en/products/detail/laird-technologies-emi/BMI-S-201-C/2175914 Solder on, bottom piece: BMI-S-201-F https://www.digikey.com/en/products/detail/laird-technologies-emi/BMI-S-201-F/2175888?s=N4IgTCBcDaIEIFkCSBaAyisAGAjCgYiALoC%2BQA One Piece Shield BMI-S-101 https://www.digikey.com/en/products/detail/laird-technologies-emi/BMI-S-101/2175907 Clip Style S1811-46R https://www.digikey.com/en/products/detail/harwin-inc/S1811-46R/19200427 pickplacepodcast.com
Jul 29, 2024 · 38 min
Stencils: The Unsung Heroes of PCB Perfection Pt. 2
In this episode Chris and Melissa continue their deep dive into the critical role of stencils in electronics assembly, with expert insights from Brett Babilonia. We discuss advanced techniques for stencil design, including custom reductions, step stencils, and nano coatings to ensure optimal solder paste application. The episode also highlights the importance of thoughtful PCB design to manage costs and improve manufacturing efficiency. pickplacepodcast.com
Jul 22, 2024 · 33 min
Stencils: The Unsung Heroes of PCB Perfection Pt.1
In this episode, we dive into the crucial role of stencils in electronics manufacturing. Joined by Brett Babilonia, we explore the complexities of stencil design, including handling missing data, determining foil thickness, and ensuring optimal solder paste application. We discuss common issues, such as SMT standoffs and hybrid components. Stay tuned for for more of an in-depth continuation in Part Two. pickplacepodcast.com
May 13, 2024 · 33 min
IPC APEX EXPO Meetup Recap
In this slightly random catchup episode Chris and Melissa discuss Chris' recent trip to California where he attended IPC APEX EXPO and hosted out first Pick, Place, Podcast meetup! Huge thanks to everyone who was able to come say hi, the wonderful conversations and show suggestions! pickplacepodcast.com

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