Green Circuits

10/08/2026

Green Circuits has added a sixth SMT production line, increasing our manufacturing capacity by 20%. This is part of our continued investment in equipment, technology, and the capabilities our customers rely on as their programs move from prototype to production.

Our CRO has talked about the pace of change in the electronics industry and the need for manufacturing partners to keep pace. This investment is one way we’re doing that and ensuring we are ready for what's next.

10/01/2026

It’s time for our monthly Complex Board Spotlight, where we take a closer look at challenging PCB assemblies and the manufacturing processes behind them.

This month’s Board of the Month highlights a challenging engineering process development project involving a high-temperature BGA with 90Pb/10Sn solder balls.

The challenge?
➡️ Because the 90Pb/10Sn alloy has a liquidus temperature above 300°C, fully melting the BGA solder balls during reflow could expose the rest of the PCB and surrounding components to excessive temperatures, creating potential reliability and component-damage concerns.

The solution?
➡️To overcome this challenge, our process engineering team developed a special soldering process that attaches the BGA without melting the high-temperature solder balls.

Instead, standard solder is used to wrap around and wet the 90Pb/10Sn balls, creating a reliable connection between the BGA and PCB while keeping the balls intact.

To achieve the required solder volume, our engineers designed a step-up stencil that deposits additional solder paste specifically in the BGA ball areas. This provides sufficient solder to properly wrap around the balls while maintaining the appropriate solder paste volume for the other components on the board. This approach also allows us to maintain a lower-temperature reflow profile, reducing thermal exposure to the rest of the board and its components.

The outcome?
➡️ We successfully built all seven boards using this process, and all seven passed the customer's internal testing requirements. This is another great example of our engineering team turning a challenging manufacturing requirement into a successful production solution.

A special thanks to our Process Engineer Derek Gyotoku for his valuable contribution.

09/23/2026

In today's competitive landscape, speed is no longer a luxury—it's a requirement for successful NPI.

In our recent article, we address the top 3 challenges we see in PCB prototyping and offer actionable solutions.

Read the article here 👉 https://www.greencircuits.com/new-product-development-and-pre-production-pcb-solutions/

Quick Turn PCB Assembly is now a requirement for successful NPI. Addressing 3 challenges in PCB prototyping and solutions.

09/16/2026

Product development timelines are shrinking, leaving little room for redesigns once fabrication or assembly begins. Considering manufacturability early helps improve production readiness, reduce manufacturing risk, and accelerate time to market...

Design for Manufacturability (DFM) helps engineering teams improve PCB quality, reduce production risk, and accelerate product development.

09/09/2026

It’s time for our monthly Complex Board Spotlight, where we take a closer look at challenging PCB assemblies and the manufacturing processes behind them.

This month’s Board of the Month highlights the full manufacturing journey of a medical product, from concept and design through manufacturing, testing, and final delivery.

Complete Manufacturing Process:

⚫ PCBA Manufacturing – High-reliability printed circuit board assembly
⚫ Sub-Assembly – Mechanical and electrical integration
⚫ Complete Box Build – Final product assembly and integration
⚫ Functional Testing – Verification of product performance & functionality
⚫ Hi-Pot Testing – Electrical safety and insulation verification
⚫ Burn-In Testing – Reliability and performance validation
⚫ Final Inspection & Shipment – Finished product ready for the customer

For complex medical products, manufacturing doesn’t stop at the PCBA. The process extends through integration, testing, validation, inspection, and final delivery, with each stage playing a role in the finished product.

This project reflects a turnkey manufacturing approach, giving customers a single manufacturing partner across the product journey, from concept and design through the final finished product and market launch.

Manufactured to meet the demanding requirements of IPC Class III and ISO 13485, this product highlights the level of quality, reliability, traceability, and regulatory compliance required for medical applications.

09/02/2026

🎥 Behind the Scenes at Green Circuits 💚🎬! We’re excited to share this video that takes you inside Green Circuits’ San Jose plant — where precision meets reliability, and ideas become mission-ready electronics.

In this tour, you’ll see:
➺ Five advanced SMT lines processing high-mix, complex PCBA workloads
➺ X-ray inspection, AOI, flying probe test, and BGA rework stations
➺ Selective conformal coating systems and full assembly / box build capability
➺ Clean, ESD-controlled workflows and traceable manufacturing steps

As a certified provider under ITAR, AS9100, ISO 9001:2015, ISO 13485, and J-STD-001 / IPC-A-610 standards, we don’t just talk compliance, we embed it into every process.

If you’re attending trade shows in the area or planning a facility visit, we’d love to host you in person. Come see how we translate certifications and capability into real, dependable performance for OEMs in aerospace, medical, defense, IoT, and more.

👉 Ready to visit? Message us and let’s arrange a walk-through.



Michael W. Hinshaw, Jr. Adam Szychowski Kaitlyn Muhlenforth Mark Evans

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Take a behind-the-scenes look at Green Circuits — a trusted leader ...

08/31/2026

It’s time for our monthly Complex Board Spotlight, where we highlight challenging PCB assemblies our team has built and the manufacturing processes behind them.

This month's Board of the Month showcases the expertise of our Design & Layout team. This high-speed interface board incorporates advanced technologies, including 10G Ethernet, DDR4, and USB, to deliver high-performance connectivity and reliability.

Designed using Altium Designer, this complex PCB features:

⚫ 18-layer PCB stack-up
⚫ 1,822 components
⚫ HDI (High-Density Interconnect) construction
⚫ Differential pair routing with length matching
⚫ Back-drill PCB technology for enhanced signal integrity

High-speed designs leave little room for error. We develop complete schematics, execute complex PCB layouts, and deliver fully functional, production-ready hardware that meets demanding performance and quality requirements.

Projects like this highlight the technical challenges behind modern PCB design and the level of precision required to bring complex hardware from concept to reality.

08/26/2026

PCB cleaning isn’t one-size-fits-all!

Our standard process uses heated deionized water to remove flux residue and contaminants. But for assemblies with more specific cleanliness requirements, we also have a chemical pre-wash system available.

While we only use the chemical pre-wash about 5% of the time, having it in-house means we can match the cleaning process to the requirements of the build, rather than taking the same approach with every assembly.

Even the cleanest assembly processes sometimes need an extra touch ...

08/20/2026

Turning Green Circuits into a cartoon surrounded by our favorite things? Say less.

✔️ High-reliability PCB assemblies
✔️ Aerospace
✔️ Medical
✔️ Defense
✔️ Quality, traceability, compliance — every time

If you’re looking for a manufacturing partner that takes specs seriously (and maybe enjoys exceeding them), let’s talk.

08/17/2026

Speed and discipline don't have to be at odds. In quick-turn PCBA, speed is important. But moving quickly only works when the process is disciplined enough to keep up.

That discipline matters even more when a project moves from NPI into production. The way a board is built, tested, and refined during NPI can directly impact how smoothly it transitions into production.

The best manufacturing processes are designed for both. Move quickly when the program needs it, while keeping the controls and consistency needed to build it right.