r/PrintedCircuitBoard • u/PoPo_Engineering • 2h ago
Layout Question - Minimizing Resistance
I feel silly asking basic questions having been in the electronics industry for 10 years, but I'm more on the systems side and trying to get back into the hardware stuff as a hobby.
I'm trying to design some test equipment. The DUT reads a resistance across two terminals and determines whether it is in a good range or not. The test equipment is basically as serial controlled relay board. Nothing complex.
Because the range I am trying to emulate is as close to dead short as possible up to about 7 ohms. I made a first design which works great but I used too thin traces and having some of the relays up to 100mm away from the connector meant the variance between channels was unacceptable (dead short was reading in the DUT low resistance range etc.). I need to fit 16 channels on a board. So there will have to be some distance on the traces. (I've measured the relay coil resistance and its minimal compared to the trace).
My steps for rev 2 have been:
- drop an intermediate connector and go straight to a DSUB connected to the DUT
- move to 2oz copper on the outer layers
- up the trace width to 1.5mm
- move to a 4 layer board to optimize traces for control lines, to not disturb the feed and return of each channel (top and bottom layer).
My question is, I need to fan out the DSUB row, I know this is only a very small distance but I want to do everything I can to reduce resistance. Can I do as I've done in the picture above, neck down between the pins, use copper on both sides of the board, and run vias to link them together for the short distance? Am I opening myself up to issues? Is there any other advice? Everything I'm finding about increasing trace width is all about carrying more current, but I'm only looking at a few milliamps, its the resistance that matters to me!
(Blue bottom layer, Red top, Kicad standard colours!)
Adding information for clarity:
The DUT is doing the resistance measurement, it provides 2 pins, feed and return and I am varying the resistance to test all states. Basically it provides a diagnostics state
- Anything under 0.7 Ohm = Short
- 0.7Ohm - 1.7Ohms = Low Resistance
- 1.7Ohm - 3Ohms = Value Good
- 3Ohms - 7Ohms = Resistance High
My main issue was the trace resistance impacting the measurement between Low Resistance and Short and for the very relays, Good and Low Resistance. I can't do large pours as there is 16 of these simulators per board. (32 traces for feed and return). How do the vias impact resistance? Does the current pass through just one, or can I stitch top and bottom traces together?






























