PCB interposers provide a flexible, cost-effective, and efficient solution to the challenge of semiconductor obsolescence or unavailability. When a semiconductor component becomes obsolete or has a lead time that is beyond 52 weeks, finding a direct replacement that fits the existing system’s footprint can be challenging. Interposers act as a bridge between the new component and the old system, allowing the integration of modern semiconductors into legacy systems without the need for extensive redesign.
By allowing the integration of newer semiconductor technologies into older systems, adapters and interposers ensure that these systems can continue to function and remain relevant, despite the original components being phased out or not immediately available.
THE SOLUTION
Implementing an PCB interposer (Figure 1) is typically faster than undertaking a full system redesign. This speed is crucial for industries where time-to-market and system uptime are critical factors, as interposers eliminate the need for extensive technical re-evaluation and redesign, simplifying the upgrade process. PCB buyers and engineers will learn they have options, as interposers are often more cost-effective than redesigning the entire system or equipment to accommodate new semiconductor components. This approach saves significantly in time, resources, and money.
In today’s rapidly evolving technological landscape, electronic components are the backbone of countless industries—from transportation and infrastructure to aerospace, defense, and medical devices. Electronics embedded within infrastructure items such as buses, trains, digital signage, and control units—essentially anything that requires a printed circuit board assembly (PCBA)—are expected to have a long lifespan of continuous operation, often exceeding a decade or more. The reliability and longevity of these systems are paramount, as they play critical roles in daily operations, safety, and public services.
However, the longevity of these electronic systems is increasingly threatened by component obsolescence and shortages.
Component obsolescence occurs when manufacturers discontinue components due to factors like declining demand, technological advancements, or new regulatory requirements. This issue is compounded by the fact that many components available today have a purchase availability of only about 10 years. Rapid changes in design, improved component speed and efficiency, and shifts in market demand can render older components obsolete at a pace that outstrips the lifecycle expectations of the systems that rely on them.
Understanding Obsolescence
Technological innovation accelerates component obsolescence. Newer components often outperform older ones in terms of speed, efficiency, power consumption, and functionality. As manufacturers strive to meet market demands for better performance and lower costs, they phase out legacy components that no longer align with current technology standards. For instance, the transition from through-hole components to surface-mount technology (SMT) has made many older components obsolete.
Market demand shifts can also prompt discontinuation. As consumer preferences evolve, components that once were popular may see decreased demand, making them economically unviable for continued production. This is especially true in consumer electronics, where rapid product cycles and the desire for the latest features drive constant innovation and turnover.
Regulatory changes play a significant role as well. Environmental and safety regulations, such as the Restriction of Hazardous Substances (RoHS) Directive and the Registration, Evaluation, Authorization, and Restriction of Chemicals (REACH), can make existing components non-compliant, necessitating their replacement with newer, compliant versions. Components containing lead or other hazardous substances, for example, have been phased out in favor of environmentally friendly alternatives.
Additionally, supply chain disruptions caused by natural disasters, geopolitical tensions, or global events like pandemics can abruptly impact component availability. The COVID-19 pandemic, for instance, led to factory shutdowns and logistics challenges that created widespread component shortages across multiple industries.
The Impact on Original Equipment Manufacturers (OEMs)
This dynamic environment underscores the importance of component obsolescence management for OEMs. While many governments and large customers assume the electronics they purchase will last more than 10 years, OEMs recognize that components used today may be discontinued within five to 10 years of the original design. Industries such as aerospace, defense, and medical devices are particularly vulnerable due to their reliance on long product lifecycles and the critical nature of their applications, where failures can have severe consequences.
In the aerospace and defense sectors, for example, equipment is often expected to remain operational for decades. The fighter jets first introduced in the 1970s, that are still in service today, require ongoing support and maintenance of electronic systems. Similarly, medical devices like MRI machines or patient monitors have long lifespans and stringent regulatory requirements, making obsolescence a significant concern.
Strategies for Obsolescence Management
To navigate these challenges, OEMs employ strategic obsolescence management practices:
Lifecycle Planning: This involves designing products with component lifecycles in mind. Engineers select parts with longer projected availability or those sourced from multiple suppliers to reduce risk. Component lifecycle data is integrated into the design process, ensuring that the selected components align with the expected product lifespan.
Diversification of Suppliers: Relying on a single supplier can be risky. By sourcing components from multiple suppliers or using standardized components available from various manufacturers, OEMs can mitigate the impact of a supplier discontinuing a component.
Obsolescence Management Software: Advanced software tools track component lifecycles, availability, and compliance status. These tools can predict obsolescence based on market trends and manufacturer announcements, allowing OEMs to make proactive decisions.
Proactive Monitoring: Continuous monitoring of component availability, market trends, and regulatory changes helps OEMs stay ahead of potential obsolescence issues. This may involve subscribing to manufacturer notifications, industry publications, and participating in professional networks.
When faced with impending obsolescence, OEMs have several options:
1. Lifetime Buys: Purchasing a sufficient quantity of components to last the product’s expected lifespan, including future repairs and replacements. While this approach ensures availability, it ties up capital in inventory and carries the risk of excess stock if demand decreases.
2. Last-Time Buys: Securing enough components for the final production run, accepting that future needs may require redesign. This strategy limits inventory costs but may not cover long-term service and repair needs.
3. Redesigning Products: Updating the product to use newer components. This can be costly and time-consuming due to engineering efforts, testing, revalidation, and recertification processes. However, it may provide performance improvements and extend the product’s market relevance.
4. Implementing Interposers or Adapters: Using PCB interposers to integrate modern components into existing designs without extensive redesign. This solution balances cost, time, and risk.
The Role of PCB Interposers
An effective solution to component obsolescence is the use of PCB interposers or adapters. An interposer is a small electronic assembly—a custom-designed PCB (Figure 2)—that mimics the function(s) of the original integrated circuit (IC). It contains input/output (I/O) interconnects that emulate or enhance the performance of the obsolete component. Crucially, it maintains the same footprint as the original IC, allowing it to fit seamlessly into the existing system without modifying the original PCB layout.
Cross Section of PCB Interposer with BGA footprint
Advantages of Using Interposers
Cost-Effectiveness: Interposers are often more economical than full system redesigns. They eliminate the need for reengineering the entire system, retooling manufacturing processes, and recertifying the product, saving significant time and resources.
Faster Implementation: They can be developed and deployed more quickly than undertaking extensive redesigns. This speed is crucial in industries where time-to-market is critical, and delays can lead to lost revenue or market share.
Risk Mitigation: By avoiding gray-market purchases or last-minute buys, interposers reduce the risk of acquiring counterfeit or substandard components. They ensure consistent quality and compliance with regulatory standards.
Extended System Life: They enable the continued use of legacy systems by integrating new technologies, delaying the need for complete system overhauls. This is particularly valuable for systems that are costly or impractical to replace entirely.
Design and Manufacturing Considerations
Designing an interposer involves several technical challenges:
Compatibility: Ensuring the new component’s electrical characteristics align with the legacy system, including voltage levels, timing, and signal integrity. Mismatches can lead to malfunctions or reduced performance.
Physical Constraints: Matching the original component’s footprint and connection interfaces. The interposer must fit within the existing space and connect seamlessly with other components.
Thermal Management: New components may have different thermal profiles. The interposer design must account for heat dissipation to prevent overheating and ensure reliability.
Quality Assurance: Rigorous testing is essential to validate performance and reliability. This includes functional testing, environmental stress testing, and compliance with industry standards and certifications.
Manufacturing Processes: The interposer must be manufacturable using standard processes to ensure scalability and cost-effectiveness. This includes considerations for surface-mount technology (SMT) assembly and compatibility with existing manufacturing equipment. (Figure 3)
Size comparison of BGA interposer
Alternative Solutions
Other strategies to address component obsolescence include:
Emulation with FPGAs: Using Field-Programmable Gate Arrays to replicate the functionality of obsolete components. FPGAs offer flexibility and can be reprogrammed as needed but may have higher costs and power consumption.
Aftermarket Suppliers: Partnering with authorized suppliers specializing in obsolete components. While this can provide short-term solutions, availability may be limited, and prices can be significantly higher due to scarcity.
Software Solutions: Implementing firmware updates or virtualization to extend hardware functionality. This can include modifying software to compensate for hardware changes or offloading certain tasks to software.
Reverse Engineering: Recreating the obsolete component by reverse-engineering its functionality. This can be complex and may raise intellectual property concerns.
Financial Implications
Obsolescence management decisions have significant financial impacts:
Inventory Costs: Lifetime buys tie up capital in inventory that may become obsolete or exceed actual demand. There are also costs associated with storage, insurance, and potential degradation of components over time.
Redesign Expenses: Engineering costs for redesigning and revalidating products can be substantial. This includes labor, prototyping, testing, and certification fees.
Opportunity Costs: Delays in addressing obsolescence can lead to lost market opportunities, customer dissatisfaction, or contractual penalties for failing to deliver products on time.
Cost-Benefit Analysis: OEMs must conduct thorough analyses to determine the most cost-effective approach, balancing short-term expenses against long-term benefits and risks.
Future Trends and Technologies
Emerging trends offer new avenues for obsolescence management:
Modular Design: Building products with interchangeable modules simplifies future upgrades and replacements. This approach enhances flexibility and can extend product lifecycles.
Additive Manufacturing: 3D printing can produce obsolete components or custom interposers on-demand, reducing lead times and eliminating minimum order quantities.
Artificial Intelligence: AI-powered supply chain management tools can predict obsolescence and optimize inventory, enhancing proactive strategies. Machine learning algorithms analyze vast amounts of data to identify patterns and forecast trends.
Internet of Things (IoT): Connected devices can provide real-time data on component performance and predict failures, allowing for timely interventions.
Supply Chain Management and Risk Mitigation
Effective supply chain management is crucial:
Globalization Effects: Diversifying supply chains reduces dependence on specific regions susceptible to disruptions. OEMs may source components from different geographical areas to mitigate risks.
Lead Time Management: Adjusting production schedules and exploring alternative components to handle extended lead times. This may involve redesigning products to use readily available components.
Supplier Relationships: Strong partnerships provide early warnings about obsolescence and collaborative problem-solving opportunities. Suppliers may offer insights into industry trends and advance notice of discontinuations.
Contingency Planning: Developing backup plans, such as qualifying secondary components or suppliers, ensures continuity in case of unexpected disruptions.
Environmental and Ethical Considerations
Addressing obsolescence responsibly contributes to sustainability:
E-Waste Reduction: Extending product lifecycles reduces electronic waste, benefiting the environment. This aligns with global efforts to minimize the environmental impact of technology.
Corporate Responsibility: Ethical practices in obsolescence management reflect positively on company reputation. Companies committed to sustainability may gain competitive advantages and customer loyalty.
Consumer Awareness: Educating customers about product longevity and sustainability fosters trust and can influence purchasing decisions. Transparent communication about obsolescence risks and mitigation strategies enhances customer relationships.
Case Studies and Success Stories
Real-world examples highlight successful obsolescence management:
Test & Measurement: A test equipment OEM faced several microprocessor shortages used in several dozen of their product lines. Instead of a numerous complete system redesign, they developed several PCB interposers that would accommodate a newer processor. These on-the-spot solutions maintained system integrity, met regulatory requirements, and
saved millions in redevelopment costs and time to market.
Transportation Sector: A rail system operator relied on legacy signaling equipment with obsolete components. Partnering with an aftermarket supplier, they secured necessary components and used interposers to integrate modern equivalents. This prevented service disruptions and avoided the high costs of overhauling the signaling infrastructure.
Conclusion
Obsolescence is a risk that cannot be overlooked. OEMs must proactively manage this risk to ensure product longevity, reliability, and customer satisfaction. By leveraging strategies like using PCB interposers, diversifying suppliers, embracing new technologies, and implementing robust obsolescence management plans, OEMs can effectively address component shortages and IC obsolescence.
Implementing comprehensive obsolescence management not only mitigates risks but also provides a competitive advantage. It ensures the continued operation of critical systems, supports sustainability efforts, and aligns with regulatory requirements. Companies that excel in this area are better positioned to respond to market changes, maintain customer trust, and uphold their commitments to quality and reliability.
Final Thoughts
In an era of rapid technological change and global interconnectedness, the ability to adapt is essential. OEMs that prioritize obsolescence management position themselves for long-term success, maintaining the integrity of their products and the trust of their customers. Embracing innovative solutions, fostering collaborative relationships across the supply chain, and committing to sustainable practices will be key to navigating the challenges of component shortages and IC obsolescence.