Quirky Electronics Manufacturing Terms

January 31, 2025

Quirky Electronics Manufacturing Terms

The world of electronics manufacturing isn’t all soldering and circuitry. Alongside the precision and science, it’s a world filled with quirky, funny and odd terms that have emerged from decades of problem-solving, troubleshooting and humor. These terms are not only memorable but also offer a glimpse into the creative language of the electronics manufacturing industry. Let’s explore some of the most entertaining examples.

Gull Wing
What is it: A type of surface-mount lead configuration where the leads extend outward from the component and then curve downward, resembling a seagull’s wings.

Pig Tail
What is it: Originally, a coiled wire or lead resembling a pig’s curly tail, often seen during assembly or rework processes. This has since been expanded to include any cable assembly that has a connector on one end, but bare wires on the other end. This is useful during development when a full cable configuration has not been decided upon, if splicing to other wires is expected, or if some wires will need to be soldered directly to the board or components.

Alligator
What is it: A term used to describe a type of clip or connection that clamps onto a wire or component. It is useful while testing or troubleshooting components posts, or wires that are available to clamp onto.

Dead Bug
What is it: A method of prototyping where an integrated circuit is placed upside-down (pins sticking up) and soldered directly to a board. It got its name because the upside-down IC with leads resembles a dead bug (particularly a cockroach) belly up with its legs in the air. Ideally, you would never need to dead bug an IC, but when something was missed in the circuit design or layout, it is a good option to prove out a circuit prior to re-spinning the board. It allows each pin to be wired to its desired connection.

Rail
What is it: Rail has two meanings:
• The edge or border of a printed circuit board used to support the board during assembly or testing. These get removed, or de-paneled prior to shipment.
• A Voltage Rail is the name given to a voltage supply. It usually goes to several locations and the name Rail has been often used (example – the 5V rail). Circuit boards often have several voltage rails.

Rat’s Nest
What is it: A messy and tangled set of wires or traces, typically seen during the design or prototyping phase. Usually during prototyping, issues are found and resolved by connecting points together with a wire. At times, this process is repeated over and over until it is hard to distinguish where the wires go. It can help correct design flaws, but meticulous notes should be taken since it may be almost impossible to reverse engineer a rat’s nest.

There are also some terms used in the electronics manufacturing industry to describe manufacturing defects. Many of these are even referred to in the IPC-A-610 manual.

Popcorning
What is it: The cracking or delamination of components or circuit boards due to trapped moisture expanding like popcorn. This is particularly a problem when a printed circuit board (PCB) assembly goes through a reflow cycle but can also happen during normal solder reflow operations.

How you can avoid this issue: Properly bake moisture-sensitive components before soldering to remove trapped moisture. Components have a MSL (moisture sensitivity level) assigned to them which details how long they can be exposed to the air prior to being baked. Baking these components and PCBs does so in a slow controlled fashion to allow the moisture to gracefully escape.

Tin Whiskers
What is it: Tiny, hair-like metallic filaments that grow from surfaces coated with tin, often causing short circuits, especially when components or leads are close together. These are also referred to as dendrites.

How you can avoid this issue: Use tin alloys with whisker-resistant properties and follow proper storage and handling protocols. Leaded parts help to minimize tin whiskers if RoHS is not allowed. Cleaning flux thoroughly also helps to prevent tin whiskers.

Head-in-Pillow
What is it: A soldering defect where the solder ball and component pad barely touch, creating the appearance of a head sinking into a pillow. This can also create a temperature-dependent defect (connected when hot, open when cold), or a latent defect that surfaces after vibration or general use.

How you can avoid this issue: Verify alignment of components and ensure reflow profiles are optimized for complete solder joint formation.

Tombstoning
What is it: A soldering defect where a small component, like a resistor or capacitor, stands up on one end, resembling a gravestone.

How you can avoid this issue: Carefully control reflow oven temperatures and ensure consistent solder paste deposition to prevent uneven heating.

Blowhole
What is it: A void or hole in solder joints caused by trapped gases escaping during soldering.
How you can avoid this issue: Use high-quality solder materials and preheat components to minimize gas entrapment during the soldering process.

Why These Terms Matter
These quirky terms do more than entertain—they highlight challenges and best practices within the electronics manufacturing industry. By understanding and addressing issues like “tin whiskers” or “popcorning,” manufacturers can achieve higher quality and reliability in their products.

At ACDi, we understand the quirks and challenges of electronics manufacturing. With over 40 years of experience, we pride ourselves on delivering precise, reliable and high-quality PCB design and assembly solutions. Contact us today to see how we can help bring your next project to life—quirks included.

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