How Forwessun Achieves Precision in PCB Testing

New video reveals the engineering approach behind our Smart Alignment Board innovation

When building test fixtures for mass PCB production, probe alignment is critical. Poor alignment leads to unreliable testing results and production delays. In our latest educational video, Production Manager Aidan Thomas demonstrates exactly how Forwessun ensures our test fixtures and probes are properly aligned before PCB testing begins.

With over 11 years of experience at Forwessun, from hands-on engineering to facility management, Thomas shares the practical approach that ensures our test fixtures perform reliably in production environments.

The Forwessun Innovation: Smart Alignment Board
Whilst the industry has traditionally used copper shorting plates to verify basic probe contact, Forwessun developed and introduced the Smart Alignment Board to address a more precise requirement: ensuring probes contact the exact centre of each test pad rather than making contact anywhere on the pad surface.
Our Smart Alignment Board uses a targeted design approach: test pads created at approximately 70% of the original PCB dimensions. This requires probes to achieve much higher accuracy to make contact, ensuring they hit the centre of each test point for optimal testing performance.

A Two-Stage Verification Process
Thomas demonstrates our systematic approach to fixture validation. We begin with traditional copper plate testing to confirm all probes make contact, then use our Smart Alignment Board to verify each probe contacts its target precisely where intended.

"When you're troubleshooting a fixture fault, you want to establish the basics first," explains Thomas. "But knowing your probes are contacting the centre of each test pad gives you confidence that your fixture is ready for production testing."

See the Process in Practice
The video provides a clear demonstration of both alignment tools, explaining how each works and why this two-stage approach has become fundamental to our fixture setup process. Thomas walks through the practical application and explains the engineering rationale behind ensuring proper probe alignment before production begins.
This systematic approach to fixture validation helps prevent testing issues and ensures reliable results when moving into full PCB production testing.

Interested in seeing how this testing methodology works in practice? Watch the full video  - www.forwessun.net/smart-pcb-testing to get an inside look at our Smart Alignment Board technology and the engineering thinking behind our approach to precision PCB testing.