PCBs


Built for 300 km/h: the PCBAs powering performance in Formula One


Steven Walter, operation director at DJ Assembly, explains how the company engineer’s electronics that thrive when failure isn’t an option


I


n Formula One, electronics live a hard life. They sit inches from engines running at extreme temperatures, they endure constant vibration, violent kerb strikes, and the occasional high-G impact. They are packed into impossibly tight spaces, and it’s critical they work – every single time. For DJ Assembly’s long-standing motorsport partner, Client Y, their role centres on one thing: building PCB assemblies that can survive that environment without drama. Here’s what that looks like in practice.


From design file to race-ready assembly


Everything starts before production. DJ work closely with Client Y’s engineering team to review layouts through a Design for Manufacture (DFM) lens. A DFM process focuses on:


● Pad geometry and spacing for consistent solder joints


● Stack-up suitability for vibration-heavy environments


● Component selection risk (availability, robustness, lifecycle)


● Thermal considerations during reflow The goal isn’t to redesign the product; it’s to help ensure the transition from schematic to physical assembly is controlled, repeatable and reliable, because in motorsport, unpredictability belongs on the track – not in production.


Building PCBAs for crash data systems


One set of assemblies the team manufacture supports the car’s accident data acquisition systems, meaning when a crash occurs, sensors measure acceleration forces and vehicle movement in real time. The PCBAs process and transmit that information for analysis and compliance within frameworks overseen by governing bodies. These boards don’t get the luxury of operating in calm conditions; they must continue functioning during and immediately after high-impact events. To support that, DJ’s manufacturing approach is deliberately controlled.


26 March 2026


Step 1 - Surface mount assembly High-density SMT is used to accommodate multiple sensor inputs and high-speed signal paths. Component placement accuracy is critical – not just electrically, but mechanically. Even minor misalignment can affect long-term durability under vibration. Solder paste deposition is tightly managed and stencil design and aperture control play a major role in ensuring uniform joints, particularly on fine-pitch components.


Step 2 - Reflow discipline Thermal profiling isn’t generic and profiles are tuned to the specific board design and component mix. Too much thermal stress can weaken components whereas controlled cooling ensures required ductility, reducing chance of joint fracturing. Motorsport projects demand traceability, and process stability, therefore DJ monitor and record batch consistencies as much as they possibly can.


Step 3 - Mechanical resilience Where required, assemblies may include additional reinforcement – staking or underfill – to reduce the risk of fatigue failure under sustained G-loading. The aim isn’t overengineering, it’s appropriate engineering.


Step 4 - Inspection is NOT a formality


Given the operating environment, inspection cannot just be a box-ticking exercise. Each assembly moves through Automated Optical Inspection (AOI) to verify placement accuracy and solder quality. With this in mind, DJ maintain material traceability throughout production, meaning, in a sector where development cycles are rapid and revisions are frequent, knowing exactly what went into each build is essential.


The other extreme: helmet communication PCBAs


If crash data boards are built for impact, the communication boards inside a driver’s helmet are built for constraint. For this, the DJ team manufacture ultra-compact PCBAs integrated into left and right earpieces.


Components in Electronics


These enable continuous communication between driver and pit crew – strategy updates, system alerts, and immediate feedback following an incident.


The challenges here are different: extremely limited board area, tight height restrictions, strict weight limits, and exposure to heat and moisture. Meaning the production process needs to consider:


Micro-assembly control Miniaturised assemblies demand precise paste deposition and component placement and with very fine pitch devices, small variations in volume or alignment can create issues. Process capability matters more than speed and DJ’s SMT setup is configured to handle these compact designs with stable, repeatable accuracy. After all, yield is protected not through rework, but through tight upfront control.


Environmental considerations Components are selected with operating conditions in mind, in this case that means moisture-sensitive devices are stored and handled appropriately. As a rule, DJ offer functional testing whenever possible. On projects like this that testing can be beneficial to help verify signal stability and audio clarity before integration as reliability isn’t about surviving impact, it’s about uninterrupted performance.


Managing pace without losing control


Formula One development cycles move


quickly, meaning updates are common and iterations can happen at any point. To support that tempo, DJ Assembly’s PCBA processes are structured around: controlled revision management, clear documentation and process records, and flexible production scheduling. Speed is part of the requirement—but so is consistency and the balance of this lies in maintaining disciplined process control while remaining responsive to engineering changes.


But here’s what it really comes down to


There’s nothing glamorous about solder paste inspection or thermal profiling data. But that’s where race-day reliability is built. For Client Y, DJ’s contribution is straightforward: ● Assemble boards that survive high vibration and shock


● Manufacture micro-PCBAs that perform in confined, high-temperature spaces


● Maintain process stability across repeat builds


● Provide traceability and inspection appropriate to the application In Formula One, performance margins are narrow and operating conditions are extreme. The electronics embedded in the car and helmet don’t get attention unless something goes wrong. It’s a manufacturer’s job to make sure they don’t — and that starts not at the track but on the manufacturing floor.


www.djassembly.com www.cieonline.co.uk


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