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Designing Electronics that Work Real-World Hardware Development (Hunter Scott)(Z-Library)

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If you’ve ever had a board fail on power-up, spent hours debugging a layout that “should work,” or run into a supplier problem just before a deadline—you already know this isn’t just about theory. It’s about judgment, decisions, and real-world constraints. Designing Electronics That Work is a guide to all the practical things you won’t find in a typical electronics textbook. It’s written for people who already know a little—maybe a lot—about circuits, but want to move faster, make fewer mistakes, and ship working hardware with more confidence.

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DESIGNING ELECTRONICS THAT WORK Real-World Hardware Development by Hunter Scott no starch press® San Francisco
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DESIGNING ELECTRONICS THAT WORK. Copyright © 2025 by Hunter Scott. All rights reserved. No part of this work may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage or retrieval system, without the prior written permission of the copyright owner and the publisher. First printing 29 28 27 26 25 1 2 3 4 5 ISBN-13: 978-1-7185-0336-6 (print) ISBN-13: 978-1-7185-0337-3 (ebook) Published by No Starch Press®, Inc. 245 8th Street, San Francisco, CA 94103 phone: +1.415.863.9900 www.nostarch.com; info@nostarch.com Publisher: William Pollock Managing Editor: Jill Franklin Production Manager: Sabrina Plomitallo-González Production Editor: Sydney Cromwell Developmental Editor: Nathan Heidelberger Cover Illustrator: Josh Kemble Interior Design: Octopod Studios Technical Reviewer: Eric Schlaepfer Copyeditor: George Hale Proofreader: James Brook Indexer: BIM Creatives, LLC The following images are reproduced with permission: Figures 7-16 and 7-17 courtesy of NASA Goddard Space Flight Center; Figures 6-18, 12-3, and 12-4 courtesy of Greg Davill. Library of Congress Control Number: 2025016561 For customer service inquiries, please contact info@nostarch.com. For information on distribution, bulk sales, corporate sales, or translations: sales@nostarch.com. For permission to translate this work: rights@nostarch.com. To report counterfeit copies or piracy: counterfeit@nostarch.com. The authorized representative in the EU for product safety and compliance is EU Compliance Partner, Pärnu mnt. 139b-14, 11317 Tallinn, Estonia, hello@eucompliancepartner.com, +3375690241.
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No Starch Press and the No Starch Press iron logo are registered trademarks of No Starch Press, Inc. Other product and company names mentioned herein may be the trademarks of their respective owners. Rather than use a trademark symbol with every occurrence of a trademarked name, we are using the names only in an editorial fashion and to the benefit of the trademark owner, with no intention of infringement of the trademark. The information in this book is distributed on an “As Is” basis, without warranty. While every precaution has been taken in the preparation of this work, neither the author nor No Starch Press, Inc. shall have any liability to any person or entity with respect to any loss or damage caused or alleged to be caused directly or indirectly by the information contained in it.
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To K and the kids
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About the Author Hunter Scott is an electrical and computer engineer with 15 years of experience in designing and implementing advanced hardware systems. He holds a degree in computer engineering from Georgia Tech and has taken two hardware companies through Y Combinator as a founder. He is a founding engineer at Reach Power, a long-range power beaming startup in Silicon Valley, where he leads technical strategy. He also advises startups and is a venture partner at Pioneer Fund. Scott has worked on a wide range of electronics designs, including medical devices, robotics, communications systems, and high-power millimeter wave phased arrays, and he holds several patents. His personal projects have included designing electronics for a large interactive art installation at Burning Man and developing a Twitter bot that won hundreds of contests. You can learn more about him or get in touch at http://hscott.net.
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About the Technical Reviewer Eric Schlaepfer coauthored a book of cross-sections, Open Circuits (No Starch Press, 2022), and runs an engineering-related Bluesky account, @tubetime.bsky.social, where he posts cross-section photos, shares his retrocomputing and reverse engineering projects, investigates engineering accidents, and even features the occasional vacuum tube or two. Some of his better-known projects include the MOnSter 6502 (the world’s largest 6502 microprocessor, made out of individual transistors), the Snark Barker (a retro re-creation of the famous Sound Blaster sound card), and the Three Fives and XL741 transistor-scale replica chip kits. His diploma, a BS in electrical engineering from California Polytechnic State University, San Luis Obispo, was signed by Arnold Schwarzenegger.
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BRIEF CONTENTS Acknowledgments Introduction PART I: PLANNING Chapter 1: What to Build and How to Plan for It Chapter 2: Component Specifications and Purchasing Chapter 3: Selecting Passive Components Chapter 4: Selecting Active Components PART II: DESIGNING Chapter 5: Schematic Design Chapter 6: Layout Design Chapter 7: Design for Excellence Chapter 8: Regulatory Requirements for Electromagnetic Compatibility and Immunity Chapter 9: Cost Engineering PART III: BUILDING Chapter 10: Prototyping Chapter 11: Building a Lab Chapter 12: Fabrication and Assembly Chapter 13: Testing Chapter 14: Troubleshooting Appendix A: How to Give a Demo Appendix B: Recommended Resources
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Appendix C: Example Fabrication Notes Index
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CONTENTS IN DETAIL ACKNOWLEDGMENTS INTRODUCTION What This Book Is Who This Book Is For What’s in the Book A Note on Mistakes Online Resources PART I PLANNING 1 WHAT TO BUILD AND HOW TO PLAN FOR IT Requirements and Specifications Identifying Product Requirements Writing Specifications Staying on Schedule Paying for Speed Reducing Risk Anticipating Delays Basic Manufacturing Process Steps Conclusion 2 COMPONENT SPECIFICATIONS AND PURCHASING
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How to Choose the Right Parts for Your Design Component Properties Component Packaging How to Buy Parts Selecting a Distributor Understanding How Parts Are Distributed Determining Quantity Conclusion 3 SELECTING PASSIVE COMPONENTS Capacitors Multilayer Ceramic Capacitors Aluminum Electrolytic Capacitors Film Capacitors Supercapacitors Tantalum Capacitors Capacitance vs. Frequency High-Frequency Signals Parasitic Inductance Common Capacitor Values Fail-Safe Capacitors Resistors Tolerance ESD Damage Temperature Effects High-Power Resistors Current-Sense Resistors Resistors as Voltage Dividers Common Resistor Values Inductors Switched-Mode Power Supplies
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High-Frequency Applications Ferrite Beads Power Ratings vs. Signal Ratings Temperature Effects Current Effects Connectors and Cables Connector Requirements Interference and Noise RF Connectors and Cables Safety Considerations Naming Confusion Crimped Connectors Circuit Protection Filters for Electromagnetic Interference Overvoltage Events Silicon-Controlled Rectifier Latch-Up Fuses for Overcurrent Events Reverse Bias Protection Galvanic Isolation Conclusion 4 SELECTING ACTIVE COMPONENTS Advertised vs. Actual Performance Oscillators and Crystals Power Supplies Voltage Conversion Low-Dropout Regulators Thermal Shutdown Microcontrollers Choosing the Right Microcontroller Considering Software Development Environments
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Derating the Operating Parameters RF Components Frequency-Dependent Parameters Amplifiers Transistors MOSFETs Drivers Drain-to-Source Resistance Diodes Batteries Lithium Lead Acid Alkaline Conclusion PART II DESIGNING 5 SCHEMATIC DESIGN Conventions Labeling and Organization Supplemental Information Formatting Review Checklist Debugging Ensuring Performance Capacitors for ICs Ferrite Beads Amplifiers Conclusion
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6 LAYOUT DESIGN Keys to Success Designing for Performance PCB Physics Design Tips Testing Considerations Creepage and Clearance Requirements High-Speed Design Considerations Stackup Design Layers Substrates Traces Vias A Stackup Example Thermal Considerations Common Gotchas DRC Checks Footprint Mistakes Conclusion 7 DESIGN FOR EXCELLENCE Design for Fabrication Fabricator Constraints PCB Markings Copper Thieving Panelization Design for Assembly Fiducials Markings to Aid Assembly Soldering Considerations
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Enclosures Cables and Connectors Design for Test Design for Reliability Conclusion 8 REGULATORY REQUIREMENTS FOR ELECTROMAGNETIC COMPATIBILITY AND IMMUNITY Reducing Electromagnetic Emissions Differential Pairs Signal Integrity Connectors Power Planes Shielding Conclusion 9 COST ENGINEERING Overall Strategy Cost Reduction in the Schematic Cost Reduction in the Layout Cost Reduction in Assembly Conclusion PART III BUILDING 10 PROTOTYPING The Prototyping Mindset
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The Minimum Viable Product Refining Your Prototype Intellectual Property Protection How to Speed Up Hardware Development Helpful Tools Modules, Evaluation Boards, and Breakout Boards Breadboards Prototyping Platforms RF Prototyping Tools Maintaining a Lab Notebook Notebook Options What a Notebook Should Include Conclusion 11 BUILDING A LAB Lab Safety Lab Furniture Soldering Equipment Irons Microscopes Other Equipment Lab Storage Options Test Equipment Power Supplies Multimeters Oscilloscopes Logic Analyzers Test Leads Spectrum Analyzers Vector Network Analyzers Small Hand Tools
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Conclusion 12 FABRICATION AND ASSEMBLY Preparing for Fabrication Buying Parts Finding and Working with Contract Manufacturers Respecting Your Contract Manufacturer Navigating Standards and Certifications PCB Fabrication Etching Milling Hiring a Fabricator How Assembly Works Soldering Soldering-Iron Techniques Flux Solder Alloys Solder Paste Wave Soldering Reflow Safety Tips for Assembly Documentation Tools Conformal Coatings and Potting Materials Cleaning and Storage Inspection and Testing System Integration Conclusion
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13 TESTING The Philosophy of Testing Regulatory Testing Approval Marks Electromagnetic Compatibility Battery Certification Medical Device Approval PCB Functionality Tests Board Bring-Up Test Fixtures Designing Tests The Failure Point Electrostatic Discharge Humidity How to Avoid Problems with Tests Conclusion 14 TROUBLESHOOTING Getting to the Root Cause of a Problem How Electronics Fail Practical Tips Troubleshooting Models The Medical Model for Troubleshooting Narrative-Based Troubleshooting Scientific Troubleshooting Conclusion A HOW TO GIVE A DEMO
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Knowing Your Audience Telling a Story Practical Tips B RECOMMENDED RESOURCES Tools PCB Fabrication and Assembly Contract Manufacturers Part Fabrication Materials Paperwork Shipping and Logistics Design Services Chip Fabrication Component Distributors Fulfillment C EXAMPLE FABRICATION NOTES INDEX
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