Uploaded July 2026 | Updated September 2026, 3 weeks ago
Altium Develop connects your HDI stackup, via, and clearance decisions directly to your fabricator, so you catch manufacturability issues before they cost you a board: altium.com/develop?utm_source=youtube&utm_medium=video&utm_campaign=hdi-design&utm_content=hdi-pcb-stackup-breakdown-etching-weight-via-spacing-more
High-density interconnect (HDI) PCB design lives or dies by the stackup, and in this deep dive Zach Peterson reviews a real HDI audio-interface board to show where high-density layouts go wrong. You'll see how copper weight and etching drive minimum clearance values, why a sub-1-mil solder mask sliver gets your board kicked back by the manufacturer, and how board-edge clearance and copper pullback keep SMD pads from getting cut during routing. It's a practical walkthrough of the manufacturability checks every PCB designer should run before hitting order.
The heart of the video is via strategy: why overlapping mechanically drilled blind vias can't be manufactured, and how to rebuild the stackup with a buried via and microvias plus laser drilling to get the same routing flexibility on a manufacturable board. Zach also breaks down via aspect ratio limits, prepreg thickness, and closes with a grounding-strategy lesson on analog vs. digital ground splits, net ties, return current paths, and the radiated-emissions and EMI risks of splitting your planes. Whether you're tackling your first HDI design or tightening up your DFM process, these tips will help you design boards that pass fab review the first time.
👉 Design Review Inspiration: youtube.com/shorts/n0T8qnjzvyM?feature=share
💡 Stay Connected:
Don't forget to like, comment, and subscribe for more in-depth tutorials and tips from @AltiumAcademy Share your thoughts and questions in the comments below!
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Don't forget to follow us on social to stay up-to-date on the latest Altium Academy content.
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👉 Follow Altium on Facebook: facebook.com/AltiumOfficial
The Altium Academy is an online experience created to bring modern education to PCB Designers and Engineers all across the world. Here you can access a vast library of free training and educational content covering everything from basic design to advanced principles and step-by-step walkthroughs. Join industry legends as they share their career knowledge, review real-life design projects, or learn how to leverage one of Altium's leading design tools. No matter your level of experience, the Altium Academy can help you become a better Designer and Engineer!
About Altium LLC
Altium LLC (ASX:ALU), a global software company based in San Diego, California, is accelerating the pace of innovation through electronics. From individual inventors to multinational corporations, more PCB designers and engineers choose Altium software to design and realize electronics-based products.
#Altium #HDIdesign #PCBstackup
0:00 Intro
1:15 Audio Interface PCB
3:24 Manufacturer Feedback
5:35 Board Edge Clearance
6:42 Design Rule Setup
8:07 Clearance Value Impact
9:20 Manufacturability Risk ️
10:48 Adjust Copper Weights 🪙
12:07 Blind Via Limitations
13:46 Redefine Via Structure
14:56 Core Layer Drilling
16:04 Blind Via Analysis
17:10 Grounding Strategy
18:30 Split Plane Issues ️
20:17 Susceptibility Test ️
21:43 Design Review Close
Altium Develop connects your HDI stackup, via, and clearance decisions directly to your fabricator, so you catch manufacturability issues before they cost you a board: altium.com/develop?utm_source=youtube&utm_medium=video&utm_campaign=hdi-design&utm_content=hdi-pcb-stackup-breakdown-etching-weight-via-spacing-more
High-density interconnect (HDI) PCB design lives or dies by the stackup, and in this deep dive Zach Peterson reviews a real HDI audio-interface board to show where high-density layouts go wrong. You'll see how copper weight and etching drive minimum clearance values, why a sub-1-mil solder mask sliver gets your board kicked back by the manufacturer, and how board-edge clearance and copper pullback keep SMD pads from getting cut during routing. It's a practical walkthrough of the manufacturability checks every PCB designer should run before hitting order.
The heart of the video is via strategy: why overlapping mechanically drilled blind vias can't be manufactured, and how to rebuild the stackup with a buried via and microvias plus laser drilling to get the same routing flexibility on a manufacturable board. Zach also breaks down via aspect ratio limits, prepreg thickness, and closes with a grounding-strategy lesson on analog vs. digital ground splits, net ties, return current paths, and the radiated-emissions and EMI risks of splitting your planes. Whether you're tackling your first HDI design or tightening up your DFM process, these tips will help you design boards that pass fab review the first time.
👉 Design Review Inspiration: youtube.com/shorts/n0T8qnjzvyM?feature=share
💡 Stay Connected:
Don't forget to like, comment, and subscribe for more in-depth tutorials and tips from @AltiumAcademy Share your thoughts and questions in the comments below!
👉 Subscribe for more: youtube.com/@AltiumAcademy?sub_confirmation=1
Don't forget to follow us on social to stay up-to-date on the latest Altium Academy content.
👉 Follow Altium on TikTok: tiktok.com/@altiumdesigner
👉 Follow Altium on Twitter: twitter.com/altium
👉 Follow Altium on Linkedin: linkedin.com/company/altium
👉 Follow Altium on Facebook: facebook.com/AltiumOfficial
The Altium Academy is an online experience created to bring modern education to PCB Designers and Engineers all across the world. Here you can access a vast library of free training and educational content covering everything from basic design to advanced principles and step-by-step walkthroughs. Join industry legends as they share their career knowledge, review real-life design projects, or learn how to leverage one of Altium's leading design tools. No matter your level of experience, the Altium Academy can help you become a better Designer and Engineer!
About Altium LLC
Altium LLC (ASX:ALU), a global software company based in San Diego, California, is accelerating the pace of innovation through electronics. From individual inventors to multinational corporations, more PCB designers and engineers choose Altium software to design and realize electronics-based products.
#Altium #HDIdesign #PCBstackup
0:00 Intro
1:15 Audio Interface PCB
3:24 Manufacturer Feedback
5:35 Board Edge Clearance
6:42 Design Rule Setup
8:07 Clearance Value Impact
9:20 Manufacturability Risk ️
10:48 Adjust Copper Weights 🪙
12:07 Blind Via Limitations
13:46 Redefine Via Structure
14:56 Core Layer Drilling
16:04 Blind Via Analysis
17:10 Grounding Strategy
18:30 Split Plane Issues ️
20:17 Susceptibility Test ️
21:43 Design Review Close
