High Power PCB Design: Pushing the Limits with Caleb Buck

Multidisciplinary product creation powered by your unconstrained network. Work concurrently across design, sourcing, and manufacturing with real-time insight. 35+ Years of Excellence: https://www.altium.com/develop?utm_so... Join host Zach Peterson on this episode of the OnTrack Podcast as he speaks with Caleb Buck, PCB Design Electronics Engineer at Nidec Aerospace, about the critical considerations for high power PCB design. From guitar pedal prototypes etched in his kitchen to aerospace systems handling 500+ amps, Caleb shares his journey and expertise in designing life-critical electronics. Learn about voltage isolation requirements, current distribution challenges, thermal management strategies, and the pitfalls that can lead to melting connectors and component failures. Discover practical approaches to high power design including IPC 2221 vs IPC 2152 standards, material selection for reliability, and how PCB layout dramatically affects current distribution in parallel switching circuits. Whether you're designing power electronics for automotive, aerospace, or industrial applications, this conversation provides valuable insights for pushing the boundaries of what's possible on a PCB. 👉 Resources from this episode: Connect with Caleb:   / caleb-buck-809b6a256   Learn More about PCB West: https://pcbwest.com/ 💡 Stay Connected: Don't forget to like, comment, and subscribe for more in-depth tutorials and tips from ‪@AltiumAcademy‬ Share your thoughts and questions in the comments below! 👉 Subscribe for more:    / @altiumacademy   Don't forget to follow us on social to stay up-to-date on the latest Altium Academy content. 👉 Follow Altium on TikTok:   / altiumdesigner   👉 Follow Altium on Twitter:   / altium   👉 Follow Altium on Linkedin:   / altium   👉 Follow Altium on Facebook:   / altiumofficial   The Altium Academy is an online experience created to bring modern education to PCB Designers and Engineers all across the world. Here you can access a vast library of free training and educational content covering everything from basic design to advanced principles and step-by-step walkthroughs. Join industry legends as they share their career knowledge, review real-life design projects, or learn how to leverage one of Altium's leading design tools. No matter your level of experience, the Altium Academy can help you become a better Designer and Engineer! About Altium LLC Altium LLC (ASX:ALU), a global software company based in San Diego, California, is accelerating the pace of innovation through electronics. From individual inventors to multinational corporations, more PCB designers and engineers choose Altium software to design and realize electronics-based products. #ElectronicsDesign #PCBDesign #PowerElectronics 0:00 Intro 1:02 From Guitar Pedals to Aerospace Electronics 4:12 High Reliability and Life-Critical Design Philosophy 6:11 PCB West Presentation Overview: Voltage, Current & Power 9:54 High Current Design Challenges and Heat Management 17:16 Current Distribution in Parallel FET Arrays 33:21 High Voltage Isolation Requirements 37:20 IPC 2221 vs IPC 2152 Standards Comparison 42:51 Material Selection for High Power Applications 46:12 Conformal Coating Considerations