How to Choose the Right Pitch Size for a Board-to-Board Connector?

In the intricate world of PCB (Printed Circuit Board) design, selecting the appropriate pitch size for board-to-board connectors is a decision of paramount importance. This choice not only influences the physical layout of the board but also its electrical performance and overall reliability. In this article, we explore the various factors to consider when choosing the right pitch size, supported by practical examples to aid understanding.

1. Space Constraints and the Push for Miniaturization

In the rapidly evolving electronics industry, the trend towards miniaturization is unrelenting. Consider the case of modern smartphones, where designers often opt for pitches as small as 0.4mm or 0.5mm. This allows for a denser population of connections, facilitating more features in a limited space. However, this comes with a caveat: the smaller the pitch, the higher the precision required in manufacturing, which can escalate costs.

Right Choice Case: In the design of the latest wearable fitness tracker, engineers opted for a 0.4mm pitch connector. This allowed them to pack more features into the small device, including advanced sensors and a larger battery, without increasing its size.

Wrong Choice Case: Conversely, a startup developing a compact IoT device chose a 1.27mm pitch, leading to unnecessary bulkiness and the inability to compete with sleeker, more compact designs in the market.

2. Maintaining Signal Integrity in High-Speed Applications

For applications where high-speed data transmission is crucial, like in server motherboards or high-performance computing systems, maintaining signal integrity is critical. A smaller pitch can exacerbate issues like crosstalk and electromagnetic interference. For instance, in a high-speed networking device, choosing a pitch size of 0.8mm to 1.0mm might strike the right balance between connection density and signal integrity.

Right Choice Case: A data center’s networking equipment used 0.8mm pitch connectors, balancing high-density connections with minimal crosstalk, ensuring reliable high-speed data transmission.

Wrong Choice Case: An audio interface manufacturer used a 0.5mm pitch for a high-frequency application, resulting in significant signal interference and degradation of audio quality.

3. Current Carrying Capacity for Power-Intensive Applications

In scenarios where connectors need to handle significant power, such as in industrial control systems or automotive electronics, a larger pitch is often necessary. A pitch size of 2.54mm, for example, allows for larger conductors and thus a higher current carrying capacity, crucial for these applications.


Right Choice Case: An industrial motor controller used a 2.54mm pitch connector, which effectively handled the high current requirements and ensured long-term reliability under harsh conditions.

Wrong Choice Case: A power supply unit for a gaming PC used a 1.0mm pitch connector, leading to overheating and eventual failure due to inadequate current carrying capacity.

4. Balancing Manufacturability and Reliability

The choice of pitch size also impacts the manufacturing process. For instance, in automotive electronics, where reliability is non-negotiable, a pitch size of 1.27mm is often chosen. It offers a good compromise between connector density and ease of assembly, ensuring a lower defect rate in mass production.

Right Case: An automotive sensor module featured a 1.27mm pitch connector, striking a perfect balance between high-density connections and ease of assembly, resulting in a high-yield, cost-effective manufacturing process.

Wrong Case: A small-scale IoT device manufacturer opted for a 0.4mm pitch without the necessary precision equipment, leading to a high defect rate in production and increased costs.

5. Cost Considerations and Industry Standards

Cost is a decisive factor in any design decision. Smaller pitches typically mean higher costs due to the precision required in manufacturing. Moreover, adhering to industry standards can be more cost-effective. For example, in consumer electronics, standard pitch sizes like 0.5mm or 0.8mm are often preferred due to the widespread availability of compatible components.

Right Case: A consumer drone manufacturer adhered to the standard 0.5mm pitch, benefiting from the cost-effectiveness and availability of standard components, ensuring a competitive market price.

Wrong Case: An experimental tablet design used a non-standard 0.65mm pitch, incurring higher costs for custom components and longer lead times, ultimately impacting its market viability.

Selecting the right pitch size for board-to-board connectors is a nuanced decision that hinges on a balance of space availability, signal integrity, current capacity, manufacturability, and cost.

By carefully considering these factors, designers can make informed decisions that enhance the performance and reliability of their electronic devices. Whether in the realm of compact consumer electronics or in the demanding environments of industrial applications, the right pitch size is key to successful PCB design.