Relocating manufacturing to the West requires more than moving factories.

For much of the past decade, many have touted the reshoring of electronics and especially printed circuit boards and electronic assemblies. Many reasons have been cited as to why reshoring is now taking place, from supply chain difficulties to nationalism, to the marketing optics of where products are made.

Indeed, no matter where you are from, it is always a nice feeling to buy locally, and while supply chain issues have been a serious problem over the past few years thanks in large part to tariffs and Covid, these challenges have seemed to impact all parts of the world relatively similarly. Because – or despite – these desires and challenges, the rate of reshoring, as measured by employment expansion, has been escalating, with the estimated annual number of jobs created attributed to reshoring topping 350,000 in the US alone.

That said, the challenges in successfully reshoring are still significant and basing success purely on employment levels may be misleading. Looking at the challenges, there have always been four: capital, facilities, technology and people, with now the possible addition of a fifth, inflation, to contend with. And two on the list may end up putting a cap on reshoring, at least in certain industries.

To close the gap in IC substrates, buyers need skin in the game.

The CHIPS Act was passed more than a year ago and not one federal dollar has yet to be awarded – although private industry has committed and started to spend billions. Once funded, the new, more advanced foundries will take years to build and start operations.

When produced, however, the chips will be useless until they are packaged and mounted on PCB platforms. The facilities, materials and knowhow to produce the substrates used to package them remain primarily in Asia – including China.

Notably, the cost to build and equip the necessary substrate and PCB facilities to produce HDI and UHDI (ultra-HDI) circuitry in volume is substantially more than that of a typical PCB or flex circuit factory, but far less than that needed for a foundry.

To provide incentives, US Representatives Blake Moore (R-UT) and Anna Eshoo (D-CA) this year introduced H.R.3249 – Protecting Circuit Boards and Substrates Act. This bill is the second iteration of this effort and has a long way to go in gaining cosponsors and approval.

Creating sustainable Western PCB and substrate sources will take time, and will not necessarily be in the country of use. Today just a handful of American and Western companies have the technology to produce some level of UHDI circuitry. To develop a secure source, the US will need more than government words, resolutions, bills and funds with heavy ropes (not just strings) attached: It needs active OEM investment and participation.

Are your internal processes or actions creating bad word of mouth?

Years ago, I went to a communications conference in Chicago where a Japanese quality executive discussed the reason behind Japanese companies' relentless pursuit of quality. He said it all boiled down to word of mouth. Japan's cities are densely populated. Residents use mass transit and live in apartment complexes. This executive said their studies had found that when a domestic consumer had a bad experience, they were likely to tell at least 10 people on their way home from work. Having lived in Japan, I agree with that assessment and that imagery remains in the back of my mind.

The internet has exacerbated this phenomenon. Recently, I had a client who was looking for lead database options. Other clients had said good things about a database they were using, so I did a search and came up with two options: the one with positive word of mouth and a much cheaper option with good online reviews. The first vendor I contacted required watching a demo to obtain pricing and details. Their salesperson ultimately discounted the annual price based on the low volume lead search needs of my client.

The second vendor shared pricing info and service descriptions on its website, no demo required.

A good library is built with an understanding of the manufacturing limits.

One of the primary factors in the quality of a printed circuit board design system is the makeup of the component footprints. The board can only be as good as the foundational pieces. Making it up as you go along is not a process for the long term. Errors or inconsistencies in the library account for a fair share of the feedback we receive from the fabricator. That is the wrong time to consider the fundamental building blocks of our collective occupation.

The source of the component footprints should be considered. A good cross-section of the supply chain provides the customer with schematic and layout symbols. This is, of course, to make it easier for us to implement their chips and other parts. CAD tools often come preloaded with a number of device examples to get you started.

Take those "freebies" with a grain of salt. One of the ways this kind of help can get in the way is in terms of traceability. One of the more important aspects of a good library is to have one and only one instance of a particular part. Naming conventions come into play here. Many, but not all, of the baseline libraries use naming conventions outlined by IPC-7351.