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How common is it to receive PCBs with failed or weak vias?

We had a number of flexi-rigid PCBs fabricated and assembled by a company in the UK. When the boards arrived and we tested them, we discovered a couple of failed vias, which we fixed with jumper wires. How common is it to receive PCBs with failed or weak vias?

PCB Assembly, PCB Testing
November 8, 2023

Seldom. I have seen it a couple of times (many years ago with smaller Taiwan suppliers). Cracking around the part where the through-hole plating connects to the copper on the surface. I believe it’s caused by poor control of chemicals or purity in the production process.

Frankly speaking, I would have discarded the entire batch upon finding bad vias. The later failures are almost inevitable. They probably discarded a bunch before shipping them too (assuming the boards were tested).

Oliver Smith

Oliver is an experienced electronics engineer skilled in PCB design, analog circuits, embedded systems, and prototyping. His deep knowledge spans schematic capture, firmware coding, simulation, layout, testing, and troubleshooting. Oliver excels at taking projects from concept to mass production using his electrical design talents and mechanical aptitude.

Oliver Smith

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