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The process of cost optimization in PCB design is notoriously multifaceted and time-consuming. Typically, it involves reviewing hundreds of components for cost and necessity and considering multiple optimization options for each. Each alternative option then needs to be evaluated against a sea of competitive products for technical viability and sourceability.
Needless to say, this process is time-consuming, and the chances of missing potential optimizations are extremely high. Realizing design optimizations without sacrificing functionality and reliability can be overwhelming.
Fortunately, we’ve developed Flux Copilot to be an ideal partner in your cost optimization efforts. By automatically evaluating a vast array of potential optimizations across numerous components simultaneously, Copilot can streamline your cost optimization process with unmatched efficiency. With Copilot at their side, engineers can identify more potential cost-saving measures in less time, even ones that might have been overlooked in a manual review.
Copilot then presents engineers with a comprehensive technical validation for each optimization suggestion. Armed with this data, engineers can make informed choices that balance cost savings with performance and reliability. This synergy between AI and human expertise empowers teams to tackle the cost optimization process more effectively, ensuring that no potential savings are left unexplored.
Here are some real-world examples that Flux users are already benefiting from:
BoM consolidation involves identifying outlier components that can be merged with existing values, reducing the number of unique components needed. For example, a circuit may require a unique resistance value, such as 31.23kΩ, but such a unique value is costly to source. Instead, Copilot can suggest implementing this resistance with two more standard and affordable solutions, such as a 30kΩ and 200Ω in series.
Stackup optimization analyzes project requirements such as temperature, humidity, and industry standards to determine the most cost-effective stackup material. For example, dielectric materials like FR-4 effectively balance performance and cost for consumer electronics applications. Copilot can analyze your project requirements and use them to optimize your stackup for cost efficiency accordingly.
Evaluating components for over-specification ensures that no component exceeds the necessary performance requirements, which can reduce costs. For example, assessing whether a high-performance microcontroller is necessary or if a lower-cost alternative can meet the project’s needs without compromising performance. Copilot can investigate the components in your schematic against the operating conditions of your circuit — be it power, temperature, or frequency — to ensure that no component is unnecessarily over-specified.
Identifying components in leadless packages and suggesting alternatives with leads, such as SOIC or TSSOP, can reduce manufacturing costs and improve assembly ease. This approach simplifies the assembly process and cuts down on production expenses. With Copilot, engineers can determine which components are viable for a simplified package, therefore cutting costs.
Standardizing connectors across the design enables bulk ordering, reduces costs, and simplifies inventory management. Identifying similar connectors and standardizing them helps streamline procurement and inventory processes. Copilot can interpret your design and offer suggestions for a single connector type that meets the needs of all of your board’s interfaces.
Organizing your BoM into groupings of functional blocks can allow your team to more easily compare designs across your product line. This kind of organization enables your team to identify inconsistencies across product BoMs, and then optimize your designs for better standardization and cost savings across the product portfolio. This standardization simplifies the design process and reduces component diversity, ultimately making sourcing easier and more affordable. Copilot can intelligently group your BoM into functional blocks to provide your team with better insight into standardization across your product line.
Cost savings can be achieved by replacing discrete components with integrated modules that combine multiple functionalities, such as Wi-Fi and Bluetooth, in a single module. Copilot can help you evaluate the cost-effectiveness of your current design and suggest integrated alternatives that help optimize your design.
Whether you’re an Electrical Engineer, a Product Manager, or a leader of technical teams, you and your organization will benefit from improving your cost-optimization process. More affordable designs means more affordable products for consumers, less risk for the enterprise, and increased competitive advantage for your brand. By leveraging AI-driven insights, teams can realize all of these benefits in one fell swoop.
Want to learn more about how your team can start using AI to streamline the cost optimization process? Sign up for Flux today.
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