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