Describe the change in observable terms

State the old and new condition using files, dimensions, materials or component references. Include the reason and affected product configurations. Avoid a description such as minor layout cleanup when the edit also moves ground stitching, alters a via span or changes an RF keepout.

Assign a proposed revision and retain the previous released archive unchanged. This gives reviewers a stable comparison and prevents working files from becoming an accidental manufacturing instruction.

Review impact across disciplines

Ask which electrical models, mechanical assumptions, assembly steps, fixtures and acceptance records depend on the changed feature. A material substitution may affect more than availability; a connector movement may affect both a channel and enclosure tooling. Name a responsible reviewer for each affected area.

Determine which previous test evidence remains relevant and where new verification is required. Record the rationale. Repeating every test indiscriminately wastes effort, while assuming no retest is needed because the board outline is unchanged leaves the decision unsupported.

Generate a complete release package

KiCad's command line documentation illustrates reproducible fabrication exports from a specified board input. Whether export is scripted or manual, retain the tool settings and regenerate all affected outputs from one source state. Check the resulting files rather than trusting the export action alone.

  • Update the drawing, stackup and via map where affected.
  • Identify the authoritative archive and superseded revision.
  • Record supplier questions and approved dispositions.
  • State the effective order, lot or product configuration.

Close the change with implementation evidence

Confirm which work in progress and stock are affected and obtain the appropriate disposition through the project's owners. Ensure the supplier acknowledges the released revision before applying it. A sent email is not evidence that an already running job changed.

After the revised build, link inspection and verification results to the change record. Note whether the intended problem was resolved and whether further action is needed. This turns revision history into useful engineering knowledge rather than a list of filenames.

DESIGN NOTE / SCHEMATIC

Adjacent-layer access, one connection at a time

Signal copper

Dielectric · geometry + material

Reference copper

Core or build-up dielectric

Signal copper

Illustrative only. Copper thickness, dielectric construction and via spans require a reviewed stackup.

Common questions

Does every copper change require a new revision?

Follow the project's release policy, but any change to manufacturing data needs a controlled identity and traceable authorization. Avoid unrecorded replacements under an unchanged archive name.

Can I email only the modified Gerber layer?

A complete regenerated package is usually clearer. If a controlled partial update is necessary, define exactly how it replaces the baseline and verify the assembled data set before use.

References & further reading

Method & assumptions · General design guidance. Validate the proposed construction and acceptance criteria for your project.