Independent PCBA and SMT process consulting for avionics, defense, and commercial clients
DFM review for pre-production board designs — Gerber, ODB++, BGA, component selection, and NPI support
Subject matter expert in solder paste printing, stencil design, and paste selection for high-volume and high-mix environments
Custom tooling design and fixture development to improve SMT and assembly process performance
Production SOP authorship for SMT, conformal coating, underfill, and inspection processes
Custom web application development using Next.js, React, and Supabase on Vercel
15+ Years
SMT Process & Manufacturing Engineering
Full SMT line ownership across high-volume (60K+ units/week) and high-mix/low-volume production environments in aerospace, defense, and electronics industries
Increased SMT throughput by 60%+ across multiple lines through process tuning, workflow optimization, and cross-functional coordination
Improved solder paste printing first pass yield from under 75% to over 99% via stencil redesign, paste selection, and SPI parameter optimization
Led material qualification and line-wide migration efforts that eliminated reflow process defects and reduced downtime
DFM engineering for NPI programs — PCB layout, component selection, custom parts, and manufacturability reviews from concept through mass production
IPC-A-610, IPC/WHMA-A-620, and NASA workmanship standards — Class 2 and Class 3 assemblies
Pick-and-place programming and optimization across Fuji SMT platforms; SPI, AOI, and AXI inspection process ownership
Custom JEDEC tray, matrix tray, and tooling design for automated placement and handling improvement
VBA-based automation tools for data analysis, material prep tracking, and build delay reduction
Engineering team management including direct reports across manufacturing engineering, document control, and floor support
Certifications & Standards
Qualifications
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B.S. Mechanical Engineering Technology
May 2009
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SMT Process Engineering
15+ years hands-on manufacturing experience
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IPC-A-610
Acceptability of Electronic Assemblies — Class 2 & 3
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IPC/WHMA-A-620
Requirements & Acceptance for Cable & Wire Harness Assemblies
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NASA Workmanship Standards
High-reliability electronic assembly standards
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IPC-7095 BGA X-Ray
Design & Assembly Process Implementation
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IPC-CC-830 Conformal Coating
Qualification & Performance of Electrical Insulating Compounds
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California LLC
Chris Villareale Consulting LLC — Registered in California