PCB E-TEST

Standard Electrical Testing in PCB Manufacturing

Electrical testing is an essential and non-negotiable part of bare board fabrication. At Highleap Electronics, all bare PCBs, whether single-layer, multilayer, rigid, flex, or HDI, undergo 100% electrical testing before shipment. This ensures the circuit continuity matches the original netlist, with no shorts or opens across all layers.

We strictly follow IPC-9252A standards, and provide full test coverage for every net defined in your design.

Electrical Test File Requirements

For accurate and complete testing, we recommend customers provide a netlist file (IPC-356 format) along with Gerber data. A netlist derived directly from the design source ensures high fidelity and accurate fault detection. If a netlist is not provided, we will generate one from the Gerber files for continuity testing.

Providing the design netlist:

• Increases test coverage accuracy

• Avoids discrepancies from CAM changes

• Ensures compliance with high-reliability standards

E-test Methods: Flying Probe vs. Test Fixture

At Highleap Electronics, we offer two primary electrical testing (E-test) methods for your bare PCBs: Flying Probe and Fixture-Based Testing. Each method has its unique strengths and is suitable for different stages of the production process, depending on factors such as board size, design complexity, volume, and cost-efficiency.

Flying Probe Test: Ideal for Prototypes and Small Batches

The Flying Probe Test is a flexible and cost-effective testing method, particularly suited for prototypes and small batch production. It doesn’t require custom fixture setup, allowing for fast deployment and lower initial costs.

• No Fixture Setup: Flying probe testing doesn’t require custom fixtures, making it ideal for prototypes or low-volume runs. The test points are directly probed by movable heads, which can reach various parts of the PCB without the need for additional fixtures.
• Test Precision: With the ability to test at 4mil (0.1mm) pitch, this method is perfect for high-density PCBs and designs with fine-pitch components.
• Fast Deployment: This method eliminates setup time for fixtures, allowing for a quick testing process once the netlist and Gerber data are provided.
• Cost-Effective for Small Volumes: For low-volume or custom boards, flying probe testing avoids the high upfront cost of fixture development, providing a more economical solution.

Fixture-Based Test: Best for Mass Production

The Fixture-Based Test is designed for mass production runs. It involves the creation of a custom fixture to test all board points simultaneously, which makes it faster and more cost-effective at higher volumes.

• Custom Fixture Build: This method requires an initial setup time to build the custom fixture tailored to your PCB design. However, once the fixture is in place, the test process becomes highly automated and fast.
• Simultaneous Testing: The fixture checks all test points on the PCB at once, reducing the overall test time per unit and increasing throughput in high-volume environments.
• Lower Cost for High Volumes: Although the initial cost of creating the fixture is higher, per-board test costs decrease significantly with larger production volumes, making this method more cost-effective for bulk production.
• Faster Runtime: After the fixture setup, the testing time per PCB is drastically reduced, which helps optimize production efficiency and reduce turnaround times.

Choosing the Right Method for Your Project

• Flying Probe Testing is ideal for prototypes, low-volume, and high-density designs where flexibility and fast turnaround are essential.
• Fixture-Based Testing is the best choice for high-volume production where cost per board needs to be minimized and speed is critical.

By selecting the appropriate E-test method, Highleap Electronics ensures that your boards are thoroughly tested while optimizing both quality and cost efficiency.

Transparent Testing, Quality Assurance, and Reliable Support

At Highleap Electronics, we believe that process transparency and rigorous documentation are essential parts of reliable PCB manufacturing. That’s why we offer full quality documentation upon request to support your internal QA workflows or customer audits, including:

• Electrical Test Reports
• Netlist Consistency Reports
• Microsection and Solderability Test Coupons
• Impedance Test Data (for impedance-controlled boards)
• Certificate of Compliance (CoC)

Beyond documentation, we uphold strict E-test implementation standards. Our system enables:

• Full traceability of test results for every production batch
• Automated logging and monitoring of test failure rates
• Isolated failure analysis with immediate corrective action
• Electrical verification based on the provided netlist and CAM output

This ensures that each PCBA circuit board delivered by Highleap starts with a rock-solid electrical foundation.

We stand behind every board we produce. All products are:

• 100% electrically tested
• Visually inspected and AOI-verified
• Covered by our quality guarantee—any defect caused by our process will be reworked or replaced at no charge

If you encounter any issues during assembly or final product testing, our responsive support team is here to assist with prompt technical help.

Trust Highleap for Reliable PCB E-testing

Electrical testing isn’t just a process—it’s a promise. A promise that every printed circuit board PCBA you receive from Highleap has been thoroughly verified, meets IPC standards, and is production-ready.

Whether you’re developing a complex circuit card assembly or require strict QC for high-volume PCB board manufacturing, we’re here to help you eliminate risks and deliver results.

Need fast, accurate, and compliant PCB E-testing?
Contact Highleap Electronics today to get a quick quote or request sample reports.