PCB Layout & Physical Integration#

Where ideas become geometry.

PCB layout is the phase where a schematic becomes a physical object. Traces have width, components have height, and thermal paths determine whether the board works or cooks. Layout is not a mechanical translation of the schematic — it’s a design activity that requires understanding signal integrity, power distribution, thermal management, and manufacturing constraints.

This subsection covers the general principles of PCB layout and physical integration that apply across all domains. Domain-specific layout guidance — RF trace impedance, high-speed digital routing, power plane design — lives in the relevant domain sections. Here, the focus is on the process and decisions that every layout requires.

What This Section Covers#

• Layout as Part of Design, Not Cleanup — Why layout is a design activity that shapes the circuit, not a mechanical step that follows it.
• Stackups & Materials — How layer count, copper weight, and substrate material determine impedance, coupling, and cost.
• Mechanical Constraints — Fitting the PCB inside an enclosure and respecting the physical world beyond the board edge.
• Connector Placement & Panel Design — Positioning connectors to define the physical interface and designing panels that match.
• Thermal Considerations — Managing heat as a first-class design constraint from component placement through copper pour.
• Design-for-Assembly Awareness — Designing boards that can actually be built efficiently and reliably.