DfR Solutions Reliability Designed and Delivered

DfR Solutions is the Healthcare Provider for the Electronics Industry - Say What?

Recently I, Greg Caswell, had full knee replacement surgery on my left knee to fix a problem with osteoarthritis.  I found the overall experience interesting in that the approach the doctor’s used to assess the issue, develop a plan for improving the joints capabilities and finally performing surgery as the last possibility, was similar to the Physics of Failure approach DfR Solutions uses.  

Topic: electronics failure, Electronics Reliability, reliability testing

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3 Real Life Examples of “Before a Failure” Investigations

Performing a “before a failure” investigation on electronics is typically done for various reasons.  One reason is to identify weak components or sub-systems before committing to a full-blown production run and its associated expenses.  Comparison testing of similar component parts to reduce costs and increase reliability of existing designs, or against a competitor’s offerings is another reason.  A “before a failure” investigation can validate a design to satisfy customer or market specifications, or regulatory obligations, which is common among the aerospace and medical devices fields.    

Topic: electronics failure, Electronics Reliability, reliability testing

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Identifying Common Electronic Failures

Failure analysis is the process of identifying, and typically attempting to mitigate, the root cause of a failure. In the electronics industry, failure analysis typically involves isolating the failure to a location on a printed circuit board assembly (PCBA) before collecting more detailed data to investigate which component or board location is functioning improperly.

Topic: Failure Analysis, electronics failure

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Top 5 Blog Posts from 2017

As 2017 is coming to a close, we are taking a look at our top viewed blog posts written by the expert engineers and reliability professionals at DfR Solutions.

Along with these blog posts, we have a large selection of resource materials available on electronics reliability, failure mechanisms and failure analysis.

Thank you for subscribing. Happy Holidays and Happy New Year!

Topic: IoT, Battery Reliability, DfR Solutions

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Flexible Electronics – Technology and Challenges

Electronic components have become more ubiquitous in the last few years. Thanks to technological advancement, they are finding their way into more product categories and industries than ever before. One such recent advancement is the Internet of Things (IoT), which is a network of interconnected systems that communicate using a network protocol. The difference between the current internet and IoT is the heterogeneity. Systems of different functionality, technology and applications will belong to the same communication environment. The mantra that every component and system manufacturer is adopting these days is to make things “smarter.” What started with smart phones is now evolving into the smart watch, smart home, smart city, smart grid, smart retail, smart farming and the list goes on.

Topic: IoT, Wearable Electronics

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Top Six Ways To Lower Warranty Costs


Warranty costs can be the bane of hardware companies. Think about it. One of the great benefits of a software company (whether it’s the old fashioned standalone software on a disk or the more common webservices) is no warranty. Facebook does not have any set asides for warranty claims, which can run into the billions of dollars for some companies. Billions of dollars doing nothing but acting as insurance.

Topic: Warranty costs

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Maximize Reliable Electronic Product Development Using Physics of Failure (PoF)

New product development (NPD) is often driven by cost and schedule. In the electronics industry, being first to market with a new technology or product is crucial to its success, and enhanced speed to market is what differentiates world class companies from the rest.

Topic: Design for Reliability, Physics of Failure

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Can Standards-Based Testing Prevent Lithium-Ion Battery Field Failures?

In my conversations with product engineers and designers, I often come across people who feel confident that their lithium-ion batteries are safe because they passed standards-based safety tests.  If that is indeed the case, then why did major global companies experience thermal events even after having passed compliance tests?  And that brings up a bigger question – are standards-based tests such as UL safety tests sufficient to guarantee lithium-ion battery safety?

Topic: Battery Reliability, Standards Based Testing

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How to Accurately Assess PCB Warpage and Solder Joint Fatigue in QFN Packages

Industry interest in producing thinner and smaller integrated circuit (IC) packages to match the performance of chip scale packages has resulted in the wide application of quad flat no-lead (QFN) components. However, the small-form factor of QFN packages can place solder joints at risk of coefficient of thermal expansion (CTE) mismatch, which can potentially lead to PCB warping and failure. To help mitigate this risk and accurately assess the fatigue life of solder interconnects in QFN packages, a predictive model incorporating the material and geometric parameters that influence solder joint fatigue should be used.

Topic: Physics of Failure, Solder Joint Fatigue, QFN Packages

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7 Months In: The Electronics Reliability Industry from a New Engineer’s Perspective

Dr. Natalie Hernandez has been a Product Engineer at DfR Solutions since November 2016. Before, she completed her PhD in Physics at Lehigh University and served as a graduate research assistant working on spectroscopic studies of rare-earth doped wide bandgap semiconductor materials, and has since made the jump to electronics reliability engineering. After 7 months in her new role, here are some of the key takeaways she’s learned about the industry.

Topic: Design for Reliability, Physics of Failure, Sherlock

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