At Circad Design, we understand how crucial it is to manage component ageing and obsolescence effectively to extend the life of products and maintain long-term reliability. In this article, we explore the effects of component ageing and obsolescence, and how we approach these challenges to ensure that our clients’ products continue to deliver value for years to come.
Electronic products are expected to be both highly functional and durable. However, one challenge that often goes overlooked is the impact of component ageing and obsolescence on the product lifespan. As electronic products age, the performance of components degrades, and as time passes, some parts may be discontinued. These issues can lead to increased failure rates, diminished reliability and reduced availability of replacement parts, particularly as products move toward their end-of-life (EOL) phase.
Understanding Component Ageing
Component ageing refers to the gradual degradation in the performance of electronic components over time. Every component, whether it’s a resistor, capacitor, transistor, or integrated circuit, has a defined lifespan. Factors like thermal cycling, humidity, voltage stress, and environmental conditions can accelerate the ageing process.
For example, capacitors lose their capacitance over time, especially if exposed to high temperatures or voltages. Resistors can change their resistance values, and semiconductors may experience performance degradation that leads to system instability or failure. As these components degrade, the overall reliability and functionality of the entire product can be compromised, resulting in system malfunctions, unpredictable behaviour, and ultimately, product failure.
However, in most electronics, repairability is not always a viable solution. Rather than repairing individual components, the more likely approach is the replacement of entire Printed Circuit Boards (PCBs). This highlights the need for ongoing availability of the same components and PCBs, which can become increasingly difficult as components are phased out. This is where component obsolescence presents a significant challenge.
The Issue of Component Obsolescence
While ageing is inevitable, component obsolescence adds another layer of complexity for electronic products. Components become obsolete for a variety of reasons, including manufacturers discontinuing parts, technological advances leading to better alternatives, or shifts in market demand. As a result, products relying on these components can face significant challenges in terms of availability, cost, and functionality.
Component obsolescence occurs when the parts used in an electronic design are no longer available from suppliers or when they are phased out in favour of newer technologies. This issue is particularly critical when it comes to PCBs. If the components or specific designs used within a PCB are discontinued, the entire PCB becomes at risk. In many cases, a product’s lifespan is tied directly to the continued availability of these PCBs and their components.
The challenge with obsolescence is that it’s not always easy to predict. Parts that are in wide use today may be discontinued in a few years, leaving products relying on those parts vulnerable to supply shortages. Proactively addressing component obsolescence, through proper forecasting and lifecycle management, is essential to ensure product continuity and long-term reliability.
The Effect on Product Lifespan
Both component ageing and obsolescence have a direct impact on the overall lifespan of electronic products. As components age, their functionality diminishes, leading to an increased likelihood of failure. As outlined above, these issues can lead to a gradual decline in product performance and, if not addressed, ultimately shorten the product’s useful life.
When obsolescence enters the equation, the resupply of PCBs becomes an issue. If a product’s PCB design relies on components that are no longer available, maintaining the product or keeping it operational becomes increasingly difficult. In some industries, such as aerospace or medical devices, the availability of replacement PCBs and their components is critical for ensuring continued product operation without resorting to costly redesigns or premature product retirement.
Strategies to Mitigate Component Ageing and Obsolescence
To address the challenges of component ageing and obsolescence, several strategies can be employed to prolong the product lifespan and maintain product reliability:
Design for Longevity. Choosing high-quality components that are rated for extended lifespans and using designs that can withstand the effects of environmental stresses will help ensure the longevity of the product. This can include selecting components with superior performance in extreme conditions or redundant design to mitigate single points of failure.
Lifecycle Management. By actively managing the component lifecycle, manufacturers can stay ahead of potential obsolescence issues. This involves monitoring component availability, lead times, and the potential for discontinuation. It also includes maintaining relationships with suppliers to secure long-term access to critical parts.
Obsolescence Forecasting. Forecasting when parts are likely to be discontinued is an important step in managing obsolescence. By keeping track of component lifecycle data, manufacturers can anticipate potential issues and take proactive measures such as sourcing alternative parts or designing for future upgradeability.
Alternative Sourcing and Cross-Referencing. Identifying alternative suppliers or compatible components early in the design process is key to mitigating the effects of obsolescence. By cross-referencing parts and developing an inventory of possible replacements, manufacturers can avoid delays and disruptions to the production cycle.
The Role of Circuit Design and Testing in Mitigating Risks
Good circuit design can mitigate many of the risks associated with component ageing and obsolescence. When designing electronic products, engineers must consider factors like thermal management, voltage regulation, and component tolerances to ensure that the product can continue to function reliably over its intended lifespan.
Thorough testing also plays a critical role in identifying potential weaknesses in the design and components. Accelerated life testing and environmental stress testing can simulate the long-term effects of ageing, allowing engineers to identify potential failure points early and address them before they affect the final product. At Circad Design, we ensure that our products undergo rigorous testing to guarantee that the components perform as expected throughout their entire lifecycle.
How Circad Uses This Approach to Deliver Quality to Clients
At Circad Design, we recognise the importance of managing both component ageing and obsolescence to ensure the long-term reliability of the products we design and manufacture. Our approach combines rigorous design practices with proactive lifecycle management to ensure that products continue to perform well even as components age or become obsolete.
We also offer a free design review to help clients assess their designs and identify potential issues related to ageing components or obsolescence risks. Our team works with clients to propose alternative sourcing solutions, component replacements, and design modifications that ensure product longevity and minimise the need for costly redesigns in the future.
Conclusion
Component ageing and obsolescence are inevitable factors that affect the lifespan of electronic products. By understanding these challenges and implementing proactive strategies, manufacturers can ensure that their products remain reliable, functional, and cost-effective throughout their entire lifecycle. At Circad Design, we leverage our expertise to help clients navigate these challenges, offering tailored solutions that extend product longevity and maximise return on investment.
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