The D-Code Podcast

YouTube is highly recommended for this episode, as it is all visual! Join Trevor Yancey from TechSearch International as we take a look at a few non-destructive imaging techniques with the Comet Yxlon guys, David Kruidhof and Vineeth Bastin. Join as we learn about CT scanning and laminography alongside Trevor who describes the modules we see and demonstrates a number of technologies present in the Apple Watch 10 series with cellular. Trevor and TechSearch International have been breaking down advanced technology devices and creating reports on what's found inside, and we had a blast learning about how these are used in combination. Watch, like, subscribe, and comment!

In this episode of The D Code Podcast, hosts Sean Kincaid, Daniel Stanphill, and Elias Malfavon Jr. interview John Burke, a veteran of the electronics manufacturing industry with decades of hands-on experience in SMT, reliability, and high-stakes applications like Formula 1 and surgical robotics. John shares insight into how manufacturing has changed over the years, why low-volume high-mix production is more complex than people think, and how technologies like laser soldering are reshaping what's possible. What we cover: Surface Mount Technology: from early days to modern lines Six Sigma and how it's actually used in factories High mix / low volume production and the unique challenges it brings Design for Manufacturing: not optional if you care about yield Real-world examples from F1, SSDs, and precision medical builds Laser soldering and its expanding role in production environments

New Episode Alert! The latest installment of The D Code Podcast featuring electronics industry veteran Adrian Leal. Whether you’re just starting out in PCB manufacturing or you’ve been around the block, Adrian’s insights on mentorship, networking, and ESD are pure gold. What You’ll Learn: How a mentor can accelerate your career growth Why face-to-face networking still matters and how social media amplifies it The critical role ESD plays in quality control (ESD is the silent killer) Real-world stories that prove personal connections lead to professional opportunities Takeaways to Act On: 1. Seek out and be a mentor 2. Build and nurture your network online and in person 3. Master ESD best practices before it masters you 4. Share what you know; ask why to unlock deeper insights Watch the full episode here: https://youtu.be/Y_BhzxJBnPU Listen on your favorite podcast platform: Join the conversation: What’s the best piece of mentorship advice you’ve ever received? Drop it below

Rev 2.8 - Sean Patterson on AI - an excellent high level overview When Sean Patterson "finally" decided to try out AI for a personal project, he was blown away by the time he saved. You'll hear this story and many more in this excellent brief of the power of AI for small to medium businesses. Heck, he's so passionate about this topic, he founded his own company in between the time we scheduled his interview and when we recorded! While Sean fully supports small to medium businesses in following a rough guideline of "AI First", he strongly cautions... well, let him tell you himself and just give this episode a go!

Special Edition of The D Code – Live from the SMTA Star Event We had the rare opportunity to sit down with Dr. Adam Klett of Kaizen and Mike Konrad at the SMTA Star event in Kansas for a jam-packed roundtable episode of The D Code Podcast — and this one went deep! Here are a few highlights you don’t want to miss: EIS > SIR? Dr. Klett introduced us to Electrochemical Impedance Spectroscopy (EIS) — a powerful evolution of SIR testing that uses AC signals to gather far more detailed cleanliness data from circuit boards. It's like the SIR test... with superpowers. Cleaning Isn’t Optional As Mike put it: "You can't be a little clean. You're either clean or you're not." Partial cleaning? Even worse than not cleaning at all. IPC Standards Are Changing IPC removed the “pass/fail” resistivity number now it’s on us to prove cleanliness. That means more testing, more validation, and more data-driven decisions. SMTA’s Future Focused Mission Dr. Klett is leading initiatives to bridge the generational gap in our industry developing young professionals, making technical knowledge more accessible, and building the future of electronics manufacturing. From Fab to Assembly: It All Matters We explored how everything from PCB fabrication chemistry to automated wash systems adds up in the fight against electrochemical migration, dendritic growth, and long-term field failures. This episode is PACKED with insight, especially if you work in PCBA, reliability engineering, or process validation. Tune in if you're curious about the future of board cleanliness testing and what SMTA is doing to build the next generation of industry leaders. #SMTA #ElectronicsManufacturing #EIS #SIR #Kaizen #IPC #PCBA

The Reality of PCB Manufacturing with Yash Sutariya In this episode, we dive into the real challenges facing domestic PCB manufacturing with Yash from Saturn Electronics. We talk about cost-saving design strategies, common mistakes, chemical innovations, automotive applications, and why passion and adaptability are critical for success. From etching processes to the future of automation, this one’s packed with insights you don’t want to miss. 🔹 How to optimize panelization and save costs 🔹 Why collaboration with your PCB shop matters 🔹 What's really changing in flex materials and automation 🔹 Why domestic PCB manufacturing needs your support Listen now and d-code the future of PCB production! #PCBManufacturing #SaturnElectronics #CostOptimization #Collaboration #DomesticManufacturing #Automation #DesignTips

We sat down with Zach to explore everything from AI in PCB design to the reality of design reviews, miniaturization, and the impact of tariffs on manufacturing. 👨‍🏫 Zach shared how he transitioned from hobbyist to professional, why investing in quality tools matters, and how AI won’t replace designers—but will definitely transform the workflow. 🔥 Highlights:   Why design reviews are a goldmine for learning   AI’s role in automating tedious PCB design tasks   How tariffs are shifting the global manufacturing map   The challenge of finding skilled labor in electronics   Why continuous education is non-negotiable   Inside stories from working with Altium Whether you're an engineer, designer, or just passionate about electronics, this is one you don’t want to miss.

From waste to wealth behind the scenes of metal reclaiming. Ever wondered how discarded solder dross transforms into high-purity metal? Tune in for the secrets! Stan's known as the "solder guru" for good reason he's been deep in the trenches of solder recycling and reclaiming for over two decades. We talked about how his family business was doing sustainable recycling long before it was trendy, turning solder dross and scrap paste. Stuff most people would think was trash into pure, usable metal. He shared some surprising details on how shifting from tin-lead to lead-free solder has complicated recycling and even taught us a few things about why copper buildup affects solder performance on selective solder machines. If you're into PCB manufacturing, PCB Assembly, solder technology, or just enjoy turning waste into something valuable, you'll want to check this one out. Big thanks to Stanley Rothschild from Metallic Resources, Inc. for the chat! #PCB #Soldering #Manufacturing #Recycling #Sustainability

Jeff Leal from Axxon-Mycronic swings by the set to dispense some knowledge 😉 An interesting talk unfolded as we discussed precision dispensing and coating solutions. The cast found particular value in learning about "right sized" platforms that can allow low volume outfits an entrance into automation via desktop dispensing robots! Sean and Elias took a stroll over to the Axxon booth after this one and got the chance to check out the benchtop THT inspection platform, very innovative stuff! A big thanks to Axxon-Mycronic for supporting the cast and advancing our goals of providing meaningful and fun conversations! #qualitycontrol #inspection #automation #PCBA

The Podfather 🎤 Our friend Mike Konrad from Aqueous Technologies and the host of The Reliability Matters Podcast, takes an unfamiliar seat as a guest during IPC Apex 2025! Mike's humility won't allow him to accept the credit due to him for mentoring and helping us up on this journey. We converse about podcasting, collaboration, and even a bit about cleaning! Elias, Producer Paul, Sean, and Daniel send a heartfelt thank you to Mr. Konrad for setting us up with all the A/V for this event! These chats were slotted for 10 minutes each, but we found a way to stretch this one longer than LinkedIn can accommodate, so head over to YouTube to check out this, and all 35 interviews from Apex 2025!

⚙️ “It’s not about CPH—it’s about what you get out the door.” At IPC APEX 2025, we sat down with Tim Kang from Hanwha to talk about next-gen automation, and let’s just say—Hanwha isn’t playing catch-up… they’re setting the pace. From dual-lane ovens that run lead and lead-free at the same time, to pick-and-place systems that run two independent jobs simultaneously—we’re seeing innovation that’s pushing the boundaries of what’s possible on the production floor. 🔧 Highlights from the convo: Why CPH is overrated and output-per-day is what really matters Hanwha’s dual-lane reflow oven with independent thermal chambers—run two profiles, two speeds, no cross-contamination A dual job pick-and-place platform that supports multiple conveyor lengths and setups running at once How cart-based feeder systems reduce changeover and operator strain Why North American CMs need high-mix, low-volume friendly systems—not just speed How Hanwha engages with customers post-sale to fine-tune performance and drive continuous improvement It’s not just about selling machines—it’s about engineering solutions that actually fit the real-life factory floor. Big shoutout to Tim and the entire Hanwha team for supporting The D Code Podcast and for continuing to bring disruptive innovation to the SMT world.

🌎 “It’s not about borders—it’s about building together.” Live from the IPC APEX 2025 show floor, we caught up with Jason Wahba of JW Corporation, who crossed the border (legally 😄) from Canada to talk all things automation, global manufacturing insights, and the future of lean electronics. 🇨🇦🇺🇸 Big thanks to Jason for the Unity Pins—combining the US and Canadian flags—and for sharing some sharp insights from his recent travels through Japan and Taiwan. 🤖 Key takeaways from our convo: Why Asia is pulling ahead in automation—not just SMT, but process-wide, including low-cost cobots and automation strategies that start at the quoting phase How their “automate first” mindset allows them to price competitively, scale faster, and defend against competition long-term The biggest roadblock to adoption here? Not just cost—it’s the lack of implementation knowledge Why lean manufacturers like us can’t afford not to automate, even in high-mix, low-volume environments Why collaboration across borders and competitors isn’t just possible—it’s essential to grow the entire industry Jason brought international experience, practical advice, and a heavy dose of humor—including a salute to his $40 Harbor Freight conformal coating setup 😆 This one was part community, part case study—and all heart. Thank you, Jason and JW Corp, for supporting the podcast and the mission of growing this industry together.

You don't last 30 years in this industry unless you do things right!   Don Dennison grabs the mic in a show floor interview with Elias, Sean, and Daniel at Apex 2025. Don is in the elite camp of folks who have attended all 25 IPC Apex Expos!   We converse about the important role Technical Reps play as a conduit between their regional clients and national brands. We also had a bit of a laugh talking about the evolution of sales techniques from cold call into the digital era.   Enjoy!   #NEWTWORKING #SOLUTIONS #SMT #PCBA

"Nothing we design, nothing we make, is worth anything if no one buys it" Enter Jessica Molloy from Asteria Sales & Marketing! We chat about two key points that may resonate with you: Breaking Down Barriers: It's great to see younger professionals in electronics confidently approaching senior figures. This willingness to connect, ask questions, and learn from experience is a major cheat code for growth and innovation within our industry. We all stand to gain if we continue to foster environments where this intergenerational knowledge sharing thrives! The Veterans in our industry are so willing to chat and share their knowledge. I have heard from more than one OG, that they have seen their enthusiasm and zeal for the space, restored by mentoring the next generation. The Power of Sales & Marketing: Jessica also emphasizes the critical role of sales and marketing alongside our talented design and production engineers. Bringing our products to market requires strategic communication, understanding market needs, and building strong relationships. It's a team effort, and every function is essential for success.

Who do you call when you need root cause analysis due to PCBA related failures? Your clean chemicals provide, naturally... Denis Barbini from ZESTRON Americas mans the interview seat aside Daniel, Elias, and Sean at IPC Apex 2025! Denis shines a light on some surprising support Zestron is providing its partners, the cast was genuinely in awe of the unexpected role Denis and Co. are playing in the field! Problems and solutions, listen now! #SMT #FAILUREANALYSIS #PCBA #CLEANING

Mr. IPC himself, John W Mitchell joined The D-Code Podcast at APEX 2025. Right off the bat, he flipped the script and started the interview asking questions of us. (We got our chance to ask him questions too!) Topics like apprenticeship, which is an exciting program the IPC is sponsoring to help foster the next generation of electronics manufacturing talent. There are apprentice and pre-apprentice programs available. He also showcased how standards get developed- you can get involved! John was very candid about all things electronics and how to create an atmosphere of partnership. Elias Malfavon Jr., Sean Kincaid, Producer Paul, and Daniel Stanphill extend our sincere gratitude once again to the IPC for being an amazing partner to us! You can also view this video on our YouTube page. Please hit like and subscribe and stay tuned for new episodes coming soon!

How smart is your storage? Inovaxe extraordinaire David Ly joined us to talk about the solutions they have for the PCB assembly world. And let me tell you- They have a lot! 🎧Listen to learn about the smart racks and integration into your ERP/MRP software 🎧 This was another interview where it was hard for the guest to try and talk about their own product because the hosts could not keep their excitement contained. Can you imagine receiving and storing your parts in seconds? Can you imagine selecting your kit and all the parts you need light up on the shelves so you know what to pick? Or how about all the inventory data automatically linked from pick and place usage to your shelves? There are too many advantages to list here, listen to this fun conversation to hear more of them! As always, we thank our audience for listening and please remember to subscribe to our YouTube page and follow us on LinkedIn for more!

Gayle Towell brings the education. Seriously, between two (2!) Masters degrees, teaching, and scientific journalism, she is an explaining machine! If you are newer to surface mount and want to learn more about the miniaturization of solder paste and stencil thickness, this interview really gives a great overview. Learn how solder balls are made, how they interact with stencils and the process of selecting what Type of paste to use. Join Sean Kincaid and Daniel Stanphill as they get schooled together by Gayle and Elias Malfavon Jr., with his stencil expertise and customer feedback he obtains to consistently drive best practice improvements. Many people are out here working with area ratio and stencil thickness as their primary concerns. When you start getting into the smaller apertures on the thinner stencils, rather than focusing just on the 5 ball rule for width of aperture, you have to start considering the height of the aperture as well. Imagine dealing with such small apertures that Type 3 solder balls are actually taller than the height of the stencil, leading to shearing effects and insufficient transfer. Also, if you love sharing and teaching about SMT concepts, you just might have a superpower you didn't know about... Gayle knows hers! #smt #pcb #problemsandsolutions #solderpaste #pcbassembly

The Father of Surface Mount Technology.... Let that sink in for a moment. Phil Marcoux was gracious enough to join Elias, Daniel, and Sean for an amazing conversation starting with the contested beginnings of SMT and working up to AI and it's applications in the EMS world. Phil makes a fascinating comparison between the introduction of SMT into PCBA and where we are currently with AI He also gives praise to Sean for a recent novel idea he had during a meeting they both attended. It was truly a privilege to sit with Papa SMT, 10 minutes was no where near enough time for our inquisitive minds. Fortunately Elias may have a touch of salesmanship in him, as he asks for the sale via an on film request and acceptance from Phil for a full length Podcast episode in the near future! #SMT #PCBA #AI #LEGEND

Daniel Stanphill friend, Debbie Carboni, joined us to talk about the science they are working on at KYZEN Corporation to help people in the PCBA space. Do you use IPA in your under stencil cleaning process? Do you always use a wet pass or do you sometimes use a dry pass? She can tell you how to stabilize your processes through chemistry. They can monitor processes in real time and help you detect problems before they exist! Sean Kincaid shares a testimonial of Kyzen's thorough work instructions for how to properly prepare the cleaning system to make a chemistry switch. Also the final results on the boards being washed with the chemistry from Kyzen are beautiful. Daniel was quick to back up Sean's testimony with his positive experience getting help from Kyzen when Aurora first got their cleaning systems up and running. Also, don't miss Elias Malfavon Jr. giving Debbie a tag line she can use and tell us if you liked it! As always, please go to our YouTube page and subscribe so you can see not just the APEX videos but all of our new releases also!