The Big Challenges Driving Today's Workforce Skills Gaps

Why such an intense focus on domesticating PCB supply chains? Well, for civilians, a chip runs their daily electronics and automobiles, an important role for sure, but for the U.S. military, smart chips make smart bombs. 

However, despite its criticality, revitalizing the U.S. PCB industry requires much more than just investments in infrastructure; it requires a complete overhaul of the workforce. Employers and their partners must equip their talent with the technical expertise and the hard and soft skills necessary to maintain global competitive advantage, a far from easy feat given the highly technical, ever-evolving, and fiercely competitive nature.

Here, we examine the key challenges driving today’s workforce skills gaps in the PCB industry and explore strategic ways to bridge this determinative gap.

1. Technological Advancements Outpacing Workforce Development

Technological advancement is a good thing, improving the way we live, work, and play (and protect our national interests). It also represents a significant challenge.

Advancements such as high-density interconnect (HDI), flexible electronics and miniaturization have made electronics more powerful and versatile, but they also demand a workforce with specialized technical skills. To stay relevant, workers must now be proficient in areas like advanced design software, materials science, and precision engineering. Further complicating the matter is the rise of semiconductor technology, nanotechnology, and system-on-chip (SoC) integration, which require additional competencies that many current workers still need to acquire.

Adding further pressure to the industry are evolving customer demands, including increasing demand for more customized, high-performance electronics across automotive, telecommunications, and aerospace industries. Customers now expect highly complex, multi-layered boards with embedded components, all while maintaining shorter turnaround times and higher quality standards. As a result, workers need advanced problem-solving skills and the ability to collaborate closely with customers to meet their specific requirements.

Unfortunately, many employees in the PCB industry are trained in narrow technical roles and lack the broader, cross-functional expertise required to manage these evolving demands.

2. Mismatch Between Education and Industry Needs

Another core issue exacerbating the industry’s workforce skills gap is the misalignment between educational curricula and the practical demands of the workplace. Many educational institutions, particularly at the undergraduate and technical college levels, focus on theoretical knowledge rather than equipping students with the hands-on skills required in complex design and manufacturing processes, an issue further compounded by Industry 4.0 and the move toward automated manufacturing, such as the use of robotics and AI. The current workforce, particularly those trained decades ago, often lacks these modern competencies, making it harder for companies to adopt cutting-edge technologies at scale. This is especially problematic in specialized areas like semiconductor manufacturing, automation, and flexible electronics, where up-to-date, real-world training is critical.

As the industry continues to evolve, students who graduate without practical, industry-relevant experience are often ill-prepared for the technical realities of the job. 

3. Aging Workforce and Knowledge Transfer

As is much talked about, many experienced professionals, particularly those involved in process engineering, quality assurance, and product development, are nearing retirement. These veteran workers possess critical knowledge and skills that are difficult to replace, such as advanced circuit routing techniques, high-reliability soldering methods, and expertise in thermal management.

However, companies struggle to facilitate effective knowledge transfer between retiring and younger employees. Onboarding programs are often insufficient, and more structure is needed to develop a pipeline of proficient talent. Without a focus on mentorship and knowledge sharing, companies risk losing invaluable expertise, which could widen the skills gap even further.

4. Globalization and Complex Supply Chains

Globalization and a dynamic, high-risk environment have introduced new layers of complexity into the PCB industry. Companies must now manage international supply chains and their subsequent risks, which requires not only technical knowledge but also expertise and global awareness in areas like trade compliance, logistics, and supplier management. 

As geopolitical risks continue to evolve, companies that fail to respond quickly may experience supply chain bottlenecks, production delays, or increased costs, further widening the skills gap. Yet, workers who understand the intricacies of supply chain optimization, risk management, and global logistics are in high demand yet in short supply.

5. Sustainability and Green Manufacturing Initiatives

The electronics and PCB industries are under increasing pressure to adopt sustainable manufacturing practices, such as the use of more earth-friendly materials, energy-efficient processes, and waste-reduction strategies. However, implementing these practices requires specialized knowledge that many workers tend to lack. For instance, lead-free soldering techniques, renewable materials, and energy-efficient production methods are relatively new to the industry, and few training programs adequately cover these areas.

As the global focus on sustainability grows, companies that fail to upskill their workforce in green manufacturing practices may find themselves at a competitive disadvantage.

6. Soft Skills and Leadership Deficiencies

The need for strong leadership and soft skills has grown as the PCB industry becomes more complex. Workers are often highly specialized in technical areas but must gain the broader skills necessary for leadership roles, such as team collaboration, project and risk management, and strategic decision-making. This leadership gap poses a significant challenge for companies looking to expand their operations or adopt new technologies and processes, as strong management is critical to successful implementation and scaling.

Furthermore, companies that lack effective onboarding and career development programs may find it difficult to promote employees into leadership positions, exacerbating the skills gap in senior roles.

Addressing the Skills Gap in the PCB Industry: A Strategic Approach

The skills required today are evolving beyond traditional technical expertise, encompassing cross-functional knowledge, soft skills, and sustainability acumen. Addressing these gaps requires a multifaceted approach, emphasizing partnerships between public and private sectors, mentorship, and structured training programs.

Formal training and continuous development. By creating formal yet dynamic training programs and embracing continuous learning, employers can help close the skills gap, ensuring workers quickly attain the most relevant skills and knowledge necessary to keep up with the pace of change. Career development frameworks that promote continuous learning and skill diversification are essential for fostering these capabilities.

Partnering with educational institutions. Companies should partner with educational institutions to ensure employees receive practical, up-to-date training aligned with the industry’s ever-changing demands. 

Establishing apprenticeship programs. Programs that combine traditional education with apprenticeship models are particularly prudent, offering hands-on experience with new technologies, enabling workers to adapt quickly, and ensuring that new talent is well-prepared for the challenges of the industry.

Private/public collaborations. In some cases, chip manufacturers and educational and government institutions are going so far as partnering to build new fabs. The collaboration between Skywater, a U.S. chip maker, the State of Indiana, and Purdue University stands as a prime example, uniting in building a $1.8BN fab in West Lafayette, Indiana, and creating some 750 jobs.

Scholarships, sponsorships, and development programs. Collaboration on curriculum development, as well as the expansion of internships, co-op programs, and mentorship opportunities, can help ensure that graduates enter the workforce with the skills they need to succeed. Companies can further incentivize careers in critical fields, such as semiconductor design and supply chain management, by offering scholarships or sponsorships to students.

Structured, digitized knowledge transfer programs. Companies can strategically close their skills gap by creating structured knowledge transfer programs. Mentorship initiatives, for example, can pair younger employees with seasoned experts to facilitate on-the-job learning, ensuring that crucial knowledge is preserved as experienced workers retire. By digitizing expertise through advanced training modules, video tutorials, and internal knowledge repositories, companies can create accessible platforms for employees to continuously expand their knowledge.

Cross-functional training. As globalization presents new challenges, PCB companies must foster a more adaptable workforce. Cross-functional training that integrates both technical and soft skills is a powerful tool for getting there. By encouraging employees to develop skills in areas such as supply chain and risk management, international trade law, logistics, and contingency planning, companies can create a more versatile team capable of navigating the volatility of today’s interconnected and global marketplace.

Developing soft skills. Alongside technical training, soft skills like communication, project management, and customer collaboration are becoming increasingly important. Employee development programs that focus on these areas, in addition to technical expertise, will enable workers to succeed in roles that require cross-functional knowledge. By fostering strong communication and customer collaboration skills, companies will be better positioned to meet the growing demand for customized, high-performance electronics.

Incorporating sustainability. By upskilling workers in sustainability practices, companies can not only align with global environmental standards but also gain a competitive edge in a market that increasingly values eco-conscious production. Companies should integrate eco-friendly production techniques into their training programs, ensuring that employees can meet regulatory requirements along with the increasing demand for green technologies.

Leadership development. Training programs should help employees cultivate essential soft skills, such as problem-solving and collaboration, while also preparing them for senior roles. This is where mentorship programs can play a pivotal role, providing opportunities for less experienced employees to learn from their colleagues and helping to foster the next generation of leaders.

In closing, addressing the skills gap in the PCB industry requires a strategic, multifaceted approach. Companies can create a future-ready workforce by investing in continuous learning, fostering industry-education partnerships, implementing structured knowledge transfer programs, and emphasizing both soft skills and sustainability. Ultimately, these efforts will enable organizations to remain competitive in a rapidly evolving industry, ensuring long-term growth and success.

Altium Is Bringing Workforce Development Programs to Students and Professionals

Altium is one of the only companies in the electronics industry that has partnered with some of the biggest players to develop the next generation of engineers and manufacturing professionals. To do this, Altium created the Altium Education program in partnership with industry experts, bringing PCB design education into high school and university classrooms. The Altium Education program includes resources for instructors on how to best present and deliver the content in this important workforce development program. Best of all, anyone can access the course content for free, and students with a valid educational institution email can get a student license to Altium Designer.

Altium has also partnered with Mouser India to bring electronics engineering resources to Indian students, further expanding the reach of the Altium Education program. As one of the fastest-growing markets for electronic products, and thanks to a national focus on the growth of the Indian electronics manufacturing sector, demand for workforce development resources is expected to continue growing as the country modernizes and industrializes.

Finally, for professionals looking to increase their design expertise and capabilities, Altium Education offers professional training that will set engineers up for success as they learn Altium Designer. Because Altium Designer is the industry’s most powerful and popular PCB design application, growing professionals can give themselves a competitive edge by increasing their expertise. Major OEMs, small design firms, freelance engineers, and everyone in between use Altium Designer to design and innovate cutting-edge electronics, from complex multilayer PCBs to high-speed digital designs. The training programs offered through Altium Education cover essential topics such as schematic capture, PCB layout, simulation, and design verification, equipping engineers with the practical skills needed for real-world applications. By mastering these capabilities, professionals can contribute more effectively to their teams, deliver higher-quality products, and stay ahead in the rapidly evolving electronics industry.