Getting a printed circuit board right might not seem dramatic — until a rushed product hits the market with faults no one saw coming. So, testing a PCB board isn’t just a best practice. It’s often the only way product teams can catch silent errors before they trigger costly delays or missed deadlines.
Whether you’re refining your current checks or figuring out how to test a PCB for the first time, this guide walks through the main PCB testing methods used across the industry. Each one offers something slightly different — from fast inspection techniques to deeper tests that reveal what’s working and what isn’t.
At Altimex, we put these methods into practice every day as part of our PCB assembly process, helping teams build dependable, production-ready boards from the ground up.
Visual Inspection
Before pulling out test rigs or probes, there’s a lot you can pick up just by looking properly. Visual inspection, often the first checkpoint, gives you a quick read on whether something’s gone wrong in manufacturing.
That check might be done by eye using magnifiers, or automatically with AOI — short for automated optical inspection. AOI systems use cameras and image processing software to flag anything that doesn’t quite look right. It’s fast, fairly low-cost, and often catches problems that would otherwise go unnoticed until much later.
Here’s what teams are typically checking for:
- Solder that’s missing, uneven, or overflowing
- Components nudged slightly out of place
- Burn marks, scratches, or heat damage
- Bent pins or gaps where connections should be
So, while it’s not the most advanced technique, visual inspection is a useful first pass, especially for spotting the kind of surface faults that can cause headaches down the line.
Continuity Testing with a Multimeter
Once the board looks sound on the surface, it makes sense to check that current can actually travel where it’s meant to. That’s where a continuity test comes in — it’s basic, yes, but often surprisingly effective at picking up early-stage issues.
This type of test is usually run using a standard multimeter, with the goal of checking whether traces or connections have broken or if a joint hasn’t taken properly. It doesn’t take long, but it can save hours if it stops a faulty board slipping through.
How to run a continuity test on a PCB:
- Set the multimeter to its continuity mode — you’ll spot this by the diode symbol or a speaker icon.
- Touch the meter’s probes to both ends of the trace or connection you want to check.
- Listen for the beep or look for a near-zero reading on the screen.
If there’s silence — or the reading’s too high — that usually means the path is broken.
Used early on, a continuity test on a PCB often stops small problems from becoming production delays. It’s a simple check, but a solid one.
Power-On Functional Testing
At some point, the board needs more than a visual check or a passive probe — it has to actually perform. Power-on testing is where that happens. You apply voltage, power up the system, and watch what unfolds.
It’s often the first moment you get to see the board respond under working conditions. So, naturally, it’s where issues like short circuits or faulty components tend to reveal themselves.
Here’s what you’re looking out for:
- Components that heat up unexpectedly
- A power supply that shuts off, often a sign of a short
- Inputs or outputs not reacting as they should
This test tends to show whether everything, from resistors to microcontrollers, is behaving as expected. And while it might seem obvious, skipping it can let bigger problems creep in further down the line.
Still, this test needs a steady hand and a clear plan. Rushing in can trigger damage, especially if there’s a wiring fault or an incorrect part already in place.
In-Circuit Testing (ICT)
When speed and consistency matter — especially in larger production runs — in-circuit testing is often the method teams rely on. ICT works by placing the PCB onto a fixture lined with probes. These probes contact test points on the board, allowing you to measure things like resistance, voltage, and capacitance, without powering the board up.
In other words, each component gets its own moment under the spotlight.
ICT is typically used to:
- Identify misaligned or incorrect components
- Detect soldering issues like cold joints or opens
- Confirm that component values match the design spec
It’s especially well-suited to high-volume builds, where you’re testing dozens, sometimes hundreds, of boards in a shift. The main catch is the fixture — it takes time and budget to set up. But once it’s running, the process becomes quick, reliable, and repeatable.
So, if your PCB design is locked in and won’t change often, ICT might be the most efficient way to test at scale.
Flying Probe Testing
If you’re working with prototypes or producing in small batches, setting up an in-circuit test fixture might feel like overkill. That’s where flying probe testing steps in. It offers much of the same insight, but without the need for a custom bed of nails.
Instead, flying probe systems use movable test heads — these are guided by software to touch down on specific points across the board. No fixed jig, no tooling costs, and it adapts easily to design changes.
The trade-off? It’s a bit slower per board. But when flexibility matters more than volume, flying probe is often the smarter pick.
Boundary Scan Testing
When you’re working with compact, component-heavy boards — especially digital ones loaded with microcontrollers, FPGAs, or system-on-chip devices — physical access for probes can get tricky. That’s where boundary scan testing comes into play.
This method uses something called JTAG (Joint Test Action Group) — a built-in test feature found in many digital components. Instead of probing with hardware, the test sends signals through the device itself, checking internal and external pin connections without needing to physically touch every point.
That makes it incredibly useful when:
- Boards are densely packed with limited probe access
- You’re testing for misconfigured or missing connections
- Post-assembly checks need to avoid mechanical stress
So, while it’s not always the first method teams turn to, boundary scan is often the most practical option once physical testing hits its limits, especially for modern, high-density digital designs.
Why PCB Testing Isn’t Just About Faults
Testing a PCB board does more than just find problems — it gives teams something harder to measure: confidence. Whether you’re producing ten units or ten thousand, knowing a board’s been checked thoroughly means fewer surprises later and a stronger foundation for whatever comes next.
The choice of method — from a quick AOI pass to a full in-circuit test or JTAG boundary scan — really depends on what you’re building and how often you’re building it. Each test offers its own balance of speed, detail, and effort. And getting that balance right can make a big difference to product quality and time-to-market.
If you’re reviewing your current testing process or setting one up for the first time, we can help. Speak directly to us for assistance by contacting us.
The post How to Test a PCB Board appeared first on Altimex.
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