Printed circuit board (PCB) design and assembly demands consistency, reliability, and uncompromising quality. Whether a product is deployed in an industrial automation controller, a critical medical device, or a military satellite, the smallest failure can have severe consequences. To minimize the risk of such defects, the electronics industry relies on IPC standards: globally recognized guidelines that define the criteria for acceptable electronic assemblies.
At MJS Designs, we adhere to IPC Class 2 and Class 3 standards in our PCB design and assembly processes to ensure product reliability and durability for every application.
What Are IPC Standards?
IPC, originally known as the Institute for Printed Circuits, is an association that develops standards and expertise for various electronics industries. It sets the bar for quality, consistency, and performance. IPC standards are developed collaboratively by industry professionals, and they serve as the blueprint for the design, manufacturing, inspection, and testing of PCBs and electronic assemblies.
Some of the most relevant IPC documents include:
- IPC-2221 –Generic Standard on Printed Board Design
- IPC-2222 – Sectional Design Standard for Rigid Organic PCBs
- IPC-A-600 – Acceptability of Printed Boards
- IPC-A-610 – Acceptability of Electronic Assemblies
- IPC J-STD-001 – Requirements for Soldered Electrical and Electronic Assemblies
- IPC/WHMA-A-620 – Requirements and Acceptance for Cable and Wire Harness Assemblies
Understanding IPC Classes: Class 1, 2, and 3
IPC standards divide assemblies into three performance classes based on the intended use and level of reliability required:
- Class 1: General Electronic Products –Devices where functionality is important, but long-term reliability is not critical. These are typically simple consumer electronics such as toys, novelty items, or light-duty gadgets.
- Class 2: Dedicated Service Electronic Products – Assemblies that must function reliably in regular service conditions. This includes many industrial and commercial electronics, where consistent performance and extended life are required, but momentary failure may not be catastrophic.
- Class 3: High Performance Electronic Products – The highest level of IPC certification. Class 3 assemblies are built for applications where continued performance is critical. These assemblies are utilized in aerospace, medical devices, military systems, and other mission-critical environments.
At MJS Designs, we specialize in Class 2 and Class 3 designs and assemblies, where reliability, repeatability, and traceability are essential.
The Role of IPC in PCB Design
The reliability of a PCB starts with its design. IPC design standards ensure that the boards we layout are:
- Manufacturable – with appropriate trace widths, clearances, and via sizes
- Reliable – through best practices for current handling, controlled impedance, and thermal management
- Compliant – with downstream fabrication and assembly requirements
At MJS Designs, our engineers apply IPC-2221 and IPC-2222 principles to guide decisions such as:
- Minimum annular ring sizes and hole-to-pad ratios
- Spacing for high-voltage designs
- Controlled impedance trace layouts for high-speed digital signals
- Creepage and clearance distances for safety and regulatory compliance
- Thermal reliefs and copper balancing to prevent warping and improve solderability
By integrating these considerations into the design phase, we help our clients reduce rework, improve testability, and shorten time-to-market. Creating an IPC-compliant PCB design is the first step toward a reliable product.
What Manufacturing to IPC Standards Entails
Once a design is finalized, IPC standards continue to play a vital role throughout the manufacturing process. Manufacturing to an IPC standard includes assembling to tightly defined requirements that ensure consistency, quality, and long-term reliability, including:
- Precise Assembly Techniques: From solder paste application to reflow profiles and hand soldering, each step must be performed under strict process controls to ensure solder joints meet IPC acceptability criteria.
- Material Handling: Components and bare boards must be stored, handled, and processed in a way that prevents electrostatic discharge (ESD), moisture absorption, and contamination.
- Process Controls: IPC compliant assemblies require tightly controlled manufacturing environments to ensure reliability and long-term performance. This includes the use of air deionizers to neutralize static charges, ESD-safe workstations equipped with grounded mats and wrist straps, and deionized, filtered water for flux removal during cleaning steps.
Inspection and Quality Assurance
Inspection is a fundamental part of meeting IPC compliance, ensuring that every assembly conforms to defined workmanship, performance, and reliability standards. IPC standards such as IPC-A-610 (Acceptability of Electronic Assemblies) and J-STD-001 (Requirements for Soldered Electrical and Electronic Assemblies) provide detailed inspection criteria that guide the evaluation of every solder joint, component lead, and assembly feature.
At MJS Designs, our inspection processes are structured to meet or exceed these IPC requirements:
- Visual Inspection is performed by IPC-certified specialists trained to apply the criteria outlined in IPC-A-610 and J-STD-001. This includes examining solder joint geometry, component orientation, lead protrusion, and overall workmanship.
- Automated Optical Inspection (AOI) systems are used to detect deviations from IPC-acceptable conditions in component placement, polarity, solder coverage, and markings.
- X-Ray Inspection supports compliance by evaluating hidden solder joints (e.g., BGAs, QFNs) for voiding, bridging, and alignment in accordance with IPC standards.
Inspection in an IPC-compliant environment extends beyond detecting assembly defects; it includes verifying that every board is built to an established and measurable standard of excellence.
The Importance of IPC Training and Certification
Designing and manufacturing to IPC standards requires a skilled workforce that understands exactly what those standards entail. At MJS Designs, designers, technicians and inspectors are trained and certified to ensure IPC workmanship is upheld at every step.
Our team includes:
- CID+ Certified Designers – competent in DFM (Design for Manufacturing) and DFT (Design for Test) requirements.
- IPC-A-610 Certified Specialists – ensuring assemblies meet visual acceptability standards.
- J-STD-001 Certified Soldering Professionals – qualified to solder components to exacting tolerances.
- IPC/WHMA-A-620 Certified Technicians – proficient in mechanical assembly and cable harness standards.
- In-House IPC Trainers and Inspectors – who ensure continued compliance as manufacturing standards evolve.
This investment in training shows the MJS Designs commitment to ensuring that our PCB assemblies are designed and built by professionals who understand the critical nature of every solder joint and trace path.
Choosing the Right IPC Class for Your Project
Determining whether Class 2 or Class 3 is right for your product depends on its intended function, environment, and tolerance for failure. While Class 3 has the highest reliability requirements, not every project demands that level of rigor.
Choose IPC Class 2 when:
- Your product must perform reliably but momentary downtime is acceptable.
- The environment is stable and the design is not mission-critical.
- You need cost-effective quality suitable for most commercial and industrial uses.
Choose IPC Class 3 when:
- Your product supports life-saving or mission-critical functions.
- It operates in extreme environments such as space, military, or high-vibration industrial settings.
- There is zero tolerance for failure or field repair.
At MJS Designs, we consult closely with our clients to help determine the appropriate IPC class for each application. We design and build to the class that meets your reliability goals—without over- or under-engineering your product.
Precision, Reliability, and Peace of Mind
IPC standards are more than guidelines—they are the foundation of high-quality electronics design and manufacturing. From schematic capture and layout through assembly and final inspection, designing and building to IPC Class 2 or Class 3 ensures your product performs exactly as expected, every time.
At MJS Designs, we’ve built our reputation on delivering complex, high-reliability PCB assemblies that meet the most demanding standards in the industry. Our experienced engineering team, certified technicians, and rigorous quality processes enable us to consistently deliver IPC Class 2 and Class 3-compliant assemblies that power some of the world’s most critical systems.
Whether your product flies at 30,000 feet, or controls a factory line, you need a manufacturing partner you can trust. Contact us today for your next design and manufacturing solution.