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October 10, 2025

In this case study, Jessica Batterman, Failure Analysis Engineer at Covalent, investigates a client’s recurring issues with unexpected power cycling and intermittent connectivity in PCB components. This analysis uncovers surface voiding in PCB assemblies as the root cause. Using advanced microscopy and cross-sectional techniques, Jessica demonstrates how these microstructural defects led to compromised electrical performance. This case highlights the value of expert failure analysis in resolving complex reliability challenges in modern electronics.

Solving Power Cycling and Connectivity Failures: PCB Surface Finish Voiding Case Study