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samples. Don't celebrate just yet. You will spend a lot of time sending samples back to the
factory with notes about what it didn't quite get correct. Sometimes, the factory will mis-
interpret your instructions. I have a batch of 100 complex circuit boards that are missing
the silkscreen text because the manufacturer did not generate the silkscreen from the cor-
rect board layer ( Figure 13.4 ). Unfortunately, the error wasn't caught until after the boards
were manufactured, and the boards were rendered useless. It's much better when the error
is caught in the production sample.
(Source: Image by Kipp Bradford)
Figure 13.4 The board on the right lost information from its prototype on the left.
Figure 13.5 shows the foam insulation used in a cooling system. There is a slight offset
to the right of the holes in the bad sample that was the result of a manufacturing measure-
ment error. This caused the insulation to not fit the enclosure for which it was designed.
Fortunately, the error was corrected before volume production commenced. The manufac-
turer was able to make the correction based on the photographs, and sent the corrected
sample for validation. It took only two tries to get it right.
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