ECAD/MCAD collaboration is no longer optional — it’s survival
In this episode of the Printed Circuit Podcast, host Steph Chavez welcomes two long-time friends and PCB design veterans — Charlene McCauley, founder of McCauley Design Group, and senior PCB designer Terrie Duffy — for a conversation about real-world ECAD/MCAD collaboration. What starts as a technical discussion quickly evolves into something more: a story of grit, mentorship, and problem-solving under pressure.
ECAD/MAD Collaboration is not a luxury — it’s the baseline
Charlene and Terrie don’t just believe in ECAD/MCAD integration — they live it. From feasibility studies to production-level board layouts, the McCauley Design Group delivers high-stakes projects for clients like Dell, where a misplaced mounting hole could derail six interdependent designs.
“We’re always digging into boards to get it perfect like they want it,” Charlene said. “And then they say, ‘Can we move the mounting hole?’”
That kind of last-minute change isn’t rare. It’s daily life. And it’s exactly why real-time ECAD/MCAD collaboration — not just alignment — is non-negotiable.
“If mechanical wants to do something, I try to collaborate with them to get it done,” Charlene added. “It always works. It always comes about.”
Every millimeter matters
As Terrie put it, “The first time you spend three days rearranging a circuit because a mounting hole was off by one millimeter — you’ll never forget it.”
Today’s ultra-compact PCB designs leave no room for error. Even a half-millimeter offset can cause an inductor to clash with a thermal sink. That’s why the team constantly checks boundary rules, height restrictions, and keep-outs — sometimes even before mechanical files arrive.
Tools help, but hustle closes the gap
Charlene and Terrie have seen every form of design exchange — IDX, IDF, DXF, EMN/EMP, PDF, even napkin sketches. But when files lag behind schedule, they improvise.
“We use Kleenex boxes and Post-it notes to figure things out,” Charlene laughed. “Sometimes a Post-it does a better job than a fancy export file.”
Their approach blends technical precision with old-school craft. When they don’t have MCAD input, they search similar boards or use DXFs to reverse-engineer what’s missing.
“You do what you’ve got to do,” Charlene said. “Because once the clock starts, every delay costs money.”
One recent example of tight-knit ECAD/MCAD success? A CAM connector redesign for Dell.
“That project would have taken twice as long without collaboration,” Terrie said.
In fact, the mechanical lead on the project estimated it would’ve taken up to ten years using legacy processes. With cross-functional alignment across mechanical, electrical, and packaging teams, Charlene and Terrie helped ship it in four.
“That was a great opportunity,” Charlene said. “Building something new for the whole world — and proving it could be done.”
Mentorship, mindset, and advice for new designers
While much of the episode focused on PCB design practices, it ended on something deeper: career growth and inclusion. Charlene reflected on being the only woman in her early engineering classes and the power of persistence.
“Women in engineering — you’ve got an open door,” she said. “If you’re good at what you do and love it, the sky’s the limit.”
Terrie agreed. “Don’t let the industry intimidate you. There’s an artistic side to board design, not just math and rules.”
Charlene credits her career to strong mentors — and now pays it forward through her teaching at Austin Community College, where she first met Terrie as a student.
“She got hooked on PCB and never looked back,” Charlene said. “Now she’s teaching the class I used to teach.”
Whether you’re using state-of-the-art simulation or aligning things with a Post-it note, one thing remains true: ECAD/MCAD collaboration isn’t a feature. It’s a necessity.
“There are a lot of fancy tools out there,” Charlene said, “but at the end of the day, you’re just trying to solve problems and get things done. That’s what matters.”
Learn more expert advice on ECAD/MCAD collaboration and listen to the Printed Circuit Podcast.
