A Beginner’s Guide to Rapid Prototyping 101

We recently came across a post in an electronics forum where a hobbyist was struggling with a PCB design—a simple USB-C board with a few LEDs powered by 5V. Despite the straightforward design, they couldn’t figure out why it wasn’t working. The problem? A short between 5V and GND that went unnoticed in their design stage. For an experienced hardware developer, it was an obvious oversight, but for someone new, it became a costly and time-consuming lesson.

At our company, we specialize in rapid prototyping for various industries. Time and again, we’ve seen how simple mistakes can lead to expensive re-spins, wasted time, and blown budgets. A PCB not only costs money to manufacture—it also takes weeks to arrive and even longer if assembly is involved. That’s why we rely on a strict pre-release checklist to ensure every design is production-ready before it’s sent out.

The DRC thorws fundamental issues with the design. E.g. here it states we are missing conenction between two items. It must be fixed!

If you’re new to ECAD or looking to refine your workflow, here’s our ultimate checklist to minimize errors and maximize quality:

1. Run ERC (Electrical Rule Check)

   
   

   Start with your schematic. Don’t ignore errors or warnings—every single one should be reviewed. Warnings may sometimes be acceptable, but errors must be resolved with proper solutions, not workarounds.

   

2. Export and Review the BOM

   
   

   Open your Bill of Materials in a spreadsheet tool like Excel. Look for inconsistencies—like multiple symbols for the same component value or mismatched footprints. Verify component availability with suppliers (Digi-Key, Mouser, etc.) to avoid last-minute sourcing issues.

   

   2.2k or 2k2? Looks like the same, then why other has MPN2? It was accidental but this can confuse manufacturers or they just increase the assembly cost, because they need to maintain a second component

3. Self-Review the Schematic

   
   

   Download datasheets, reference designs, and app notes for every major component. Compare your implementation against the manufacturer’s recommendations, paying special attention to pin functions and peripheral circuits.

   

   The reference designs contains key informations for operations. E.g. the proper value/size of capacitors

4. Peer Review the Schematic

   
   

   Have a team member or colleague walk through the schematic with you. A fresh pair of eyes can catch mistakes you might have overlooked.

5. Implement Review Feedback

   
   

   Address all findings from the schematic review before moving forward.

6. Run DRC (Design Rule Check) on the Layout

   
   

   Just like ERC, ensure your layout is error-free. Examine every warning—some may be harmless, but others could indicate serious issues like insufficient clearance or missing connections. Review the stackup, the design rules itself.

7. Self-Review the Layout

   
   

   Manually check each footprint against manufacturer recommendations. Confirm pad sizes, spacing, and orientation match the datasheet.

   
   

   

   Here the pin1 is not perfect, might cause soldering issues or other operational issues if we do not follow the manufacturer recommendation

   

   Manufacturers have recommendation on component layout, distances, via placement. We should follow these

8. Generate and Inspect Gerbers

   
   

   Use a Gerber viewer to verify that all layers look correct. Pay attention to copper pours, drill holes, and silkscreen alignment. Manually go over each layer.

9. Upload to Manufacturer & Run DFM

   
   

   If your manufacturer offers a Design for Manufacturability (DFM) check, use it. It can flag issues like inadequate clearances, components too close to the board edge, or pads that may cause tombstoning.

   

   Tombstoning of SMT component by using wrong footprint or routing guides not followed

   

   DFM shows errors/warning in the point of the manufacturer

10. Peer Review the Layout

    
    

    Have someone else review the layout—another perspective is invaluable for catching potential assembly or performance issues.

    

    GND filling might affect RF operation. This might be skipped alone, but with another person view he can highlight it

11. Implement Layout findings

    
    

    Make necessary adjustments based on the layout review.

12. Package the Release Version

    
    

    Create a complete design package that includes:

    • Project files

    • BOM (CSV)

    • Schematic (PDF)

    • Layout layers (PDF)

    • Assembly drawings (PDF)

    • Pick-and-place file

    • 3D STEP file

      
      

      This ensures you—or anyone else—can easily revisit or reproduce the design months or years later.

      
      

By integrating these steps into your design flow, you’ll not only reduce errors but also optimize your boards for performance, reliability, and manufacturability. At the end of the day, following best practices saves time, money, and frustration.

Do you follow a similar checklist in your workflow? What steps have saved you from a production disaster? Share your experiences in the comments below!

#ECAD #PCBDesign #RapidPrototyping #HardwareDesign #Engineering #DFM #Electronics #BestPractices #PCBManufacturing