The first step is to define your impedance target. For single-ended traces on the PCB, the most common values are 50 Ω, 75 Ω, and 100 Ω. Differential pairs are 90 Ω, 100 Ω, and 120 Ω. Then, you’re going to have to determine the frequency range of operation, as this affects the material selection and design rules.

Start by figuring out how many layers you’ll need; more layers provide you with better control, but they also increase the cost.

Arrange the signal and plane layers, typically as signal-ground-power-signal. Then, you’ll calculate the dielectric thickness using impedance calculators or specialized software. For more complex designs, you might want to use buried and blind vias.

Use impedance calculation formulas or software to calculate trace dimensions. You’ll need to determine trace width and spacing and adjust these to calculate the impedance value. Also, keep in mind manufacturing tolerances. If you have differential pairs, you’ll have to calculate the individual trace width and the spacing between traces.

Set up the trace width and spacing rules in your CAD software and define size, spacing, and type via routes. Then you need to establish clearance rules for between traces, pads, and planes. Create length-matching rules for differential pairs.

Place components to minimize critical trace lengths. Route critical signals first with consistent width and smooth bends. Use reference planes for return paths and route differential pairs as parallel, equal-length traces with length matching. Finally, add guard traces and stitching vias to control crosstalk.

Start by performing a pre-layout simulation using tools like HyperLynx or HFSS. Then, conduct a post-layout simulation to verify impedance control and make sure to check for reflections, crosstalk, and EMI issues.

Analyze eye diagrams to ensure that signal quality meets specifications and iterate design if necessary by adjusting trace widths, spacings, or stackup.

Generate accurate Gerber files and include impedance requirements in fabrication notes. Specify impedance control requirements, including target impedances for different trace types and acceptable tolerance ranges.

Then, request impedance coupons and test structures for impedance verification. Finally, choose a PCB manufacturer experienced in characteristic impedance control, like OurPCB.

Perform Time Domain Reflectometry (TDR) measurements to verify actual trace impedance. Use Vector Network Analyzer (VNA) for high-frequency testing to measure S-parameters. Then, conduct functional testing to ensure the PCB meets performance requirements. Analyze test results and make adjustments if necessary.

• Document all design decisions and test results
• Create a report detailing impedance control achievements
• Use insights gained to improve future designs
• Consider creating design guidelines for your organization

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