Component Selection Guide
Component Selection Guide
FOR
Component Selection
Component Selection Guide Shimi Cohen - All Rights Reserved
INTRODUCTION
SELECTION FUNDAMENTALS
Modern Selection Challenges
Supply Chain Disruptions Extended lead times Strategic sourcing, alternate components
Availability:
Component availability always been a problem
Product Lifespan:
Component lifecycles constrain
Cost:
Very Important Factor
Size:
Component Dimension
Age:
Manufacturing Date
Status:
Active / NRND / Obsolete
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Component Selection Guide Shimi Cohen - All Rights Reserved
OVERVIEW
COMPONENT VARIETY
When we talk about Board Design there are families of components used in most
applications and design, some of them are passive, some are active or even semi-
conductor (diode). These are the components we will focus on:
Popular Components
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Component Selection Guide Shimi Cohen - All Rights Reserved
COMPONENTS TYPES
PASSIVE COMPONENTS
Resistor Characteristics
Resistor Parameters:
• Resistance (Ω): The primary value – opposition to current flow.
• Tolerance (%): How accurate the resistor is from its nominal value (e.g., ±1%, ±0.1%).
• Power Rating (W): Maximum heat without damage (e.g., 1/4W, 1W, 5W).
• Voltage Rating (V): Max voltage it can withstand without breakdown.
• Stability: How well the value holds over time, temperature, humidity
• Size / Package: Affects power handling and layout. E.g., 0603, 0805, axial, radial
Resistor Types:
• General: No special parameters
• Precision: Resistance Tolerance < 0.1%
• Shunt: Very Small Values for current sensing
• Power: Rated for high power (physically larger)
• Variable: Resistance Range (potentiometer)
• Photoresistor: Reflected light Changes resistance
• Thermistor: RTD / NTD / PTC
Resistor Packages:
• 0201 (0603 metric): Ultra-compact (0.6×0.3mm) for wearables/medical devices
• 0402 (1005 metric): Tiny SMD (1.0×0.5mm) for smartphones/tablets
• 0603 (1608 metric): Standard SMD (1.6×0.8mm) for consumer electronics
• 0805 (2012 metric): Mid-size SMD (2.0×1.25mm) for general-purpose circuits
• 1206 (3216 metric): Larger SMD (3.2×1.6mm) for power supplies/industrial use
• 2512 (6432 metric): High-power SMD (6.4×3.2mm) for 1W+ applications
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PASSIVE COMPONENTS
Capacitor Characteristics
Capacitor Parameters:
• Capacitance (F): primary value – ability to store electric charge
• Tolerance (%): Allowed deviation from nominal value
• Voltage Rating (V): Max continuous voltage before breakdown.
• ESR (Ω): Equivalent Series Resistance – impacts Heat/Ripple/Stability
• Dielectric Type: Material defines behavior (X7R, C0G).
• Package/Size: SMD (0402–1210), radial, axial
• Polarity: Electrolytic and tantalum are polarized
Capacitor Types:
• Ceramic – non-polarized, cheap, used for decoupling
• Electrolytic – Polarized, high cap, used for P.S smoothing
• Tantalum – Polarized, compact, stable, used in space-constrained circuits
• Film – non-polarized, stable, low loss, used in filters and timing
• Polypropylene – Film subtype, ultra-stable, great for precision and high-voltage
• Supercapacitor – Ultra-high capacitance, used for energy storage/backups
• SMD– Surface-mount version of any type above
• Radial/Axial Capacitor – Through-hole lead configurations
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Component Selection Guide Shimi Cohen - All Rights Reserved
PASSIVE COMPONENTS
Inductor Characteristics
Inductor Parameters:
• Inductance (H) – Ability to store magnetic energy; how it resists current change.
• Current Rating (A) – Max continuous current before overheating or degradation
• Saturation Current – Current where the core loses its magnetic ability
• DC Resistance (DCR) – Internal resistance of the wire; causes I²R losses and heat
• Core Material – Affects frequency response, saturation, and loss (Ferrite, Iron)
• Shielding – Reduces EMI to/from nearby components
• Tolerance (%) – How much inductance can vary from the nominal value.
• Mounting Type – SMD or through-hole; affects size, current handling, and assembly.
• Package Size / Footprint – Physical size; larger inductors handles more power.
Inductor Types:
• Toroidal – Donut-shaped core
• Common Mode Choke – Cancels noise
• Multilayer– SMD, compact
• Drum/Core - used in general power apps.
• Coupled– Two or more windings, SEPIC, Flyback
• Shielded– Magnetic shielding added; minimizes EMI,
• Unshielded– Cheaper, smaller, but higher EMI leakage.
• Surface Mount (SMD) – Small footprint for PCBs
• Power Inductor– Designed to handle high current and power, DC-DC converters.
Inductor Materials:
• Air – No core; zero core losses, ideal for high-frequency RF, but low inductance.
• Ferrite – Ceramic compound; high permeability, low loss at MHz range
• Iron Powder – Granular iron mix; decent inductance, tolerates DC bias well
• Laminated Steel/Iron – Stacked metal sheets; used in transformers
• Silicon Steel – Enhanced laminated iron; Low Freq applications.
• Ceramic – Used as non-magnetic core base in multilayer inductors, mainly for RF.
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SEMICONDUCTOR COMPONENT
Diode Characteristics
Diode Parameters:
• Forward Voltage (VF): Voltage drop when conducting forward.
• Reverse Leakage (IR): Small current under reverse bias.
• Max Forward Current (IF): Max continuous forward current.
• Reverse Voltage (VRM): Max reverse voltage without breakdown.
• Max Surge Current (IFSM): Max short-term forward current.
• Power Dissipation (P): Max heat power diode can handle.
Diode Types:
• Rectifier: Handles high current; used for AC to DC conversion.
• Schottky: Low forward voltage and fast switching
• Zener: Operates in reverse breakdown for voltage regulation.
• LED (Light Emitting Diode): Emits light when forward biased
• Power: Supports high current and voltage; used in power electronics.
• Small Signal: Low capacitance and fast recovery; used in RF
• TVS: Protect sensitive electronics from voltage spikes
Popular Packages:
• TO-220: Heatsink-compatible package for power rectifiers/Schottky diodes.
• SOD-123: SMD package for switching diodes (e.g., 1N4148W).
• SOD-323: Ultra-compact SMD for space-constrained designs (e.g., RF diodes).
• SOD-523: Miniature SMD for low-power circuits (e.g., signal clamping).
• SMA/SMB/SMC: SMD packages (DO-214AC/AA/AB)
• MELF (DO-213): Leadless cylindrical SMD for stable Schottky/Zener diodes.
• SOT-23: 3-pin SMD for diode arrays/small-signal applications.
• TO-247: Robust SMD/heatsink package for high-power rectifiers (e.g., automotive).
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ACTIVE COMPONENTS
Active components Types
Transistor
• BJT: Good for current amplifiers, analog buffers
• MOSFET: Good for everything else (Driver, Power Amplifiers)
• JFET: same as MOSFET but slower and less noisy
Operational Amplifier
• General-Purpose – Basic performance, cheap and widely used
• Precision – Low offset/drift, ideal for measurement circuits
• High-Speed – Fast response, high bandwidth for RF/video
• Low-Noise – Minimal input noise, great for audio and sensors
• Rail-to-Rail – Full swing input/output, perfect for low-voltage systems
• Low-Power – Microamp current draw, used in battery-powered devices
• Differential (Instrumentation) – Handles small differential signals
• Programmable Gain – Gain set digitally, great for analog front-end control.
• Comparator –Optimized for switching at thresholds
Voltage Regulators
• Linear Regulator – Either Fixed or Adjustable
• Low Dropout (LDO) – Efficiency depending on in/Out ration
• Buck – Higher Input Lower Output
• Boost – Lower Input Higher (or Equal) Output
• Buck-Boost – When Input range is wide and needs both Buck & Boost
• SEPIC– Buck-Boost with better ripple out
• Inverter – Input and Output are inverted
• PMIC – Programmable regulator via I2C/SPI
MCU / Others
• MCU – Microcontroller Unis (I/O, Memory, Logic)
• FPGA/CPLD – Reconfigurable Logic Blocks
• ICs – Logic Gates Timer and specific applications
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SELSCTION STRATERGIES
MULTI-SOURCING APPROACHES
When selectin components always lean towards those that can be replaced when a
problem occurs. For example, pick known footprint were you know that other
manufactures produce the same part with the same pinout.
Approach Implementation
Same Specification Identical part from multiple manufacturers
Form-Fit-Function (FFF) Different part numbers, same functionality
Functional Alternatives Different specifications but same core function
Technology Alternatives Different solution approach
FOOTPRINT STRATEGIES
Strategy Description
Thermal Relief Ensure support in thermal pads (EP)
Footprint Reuse Select Components that share footprints across the design
Hand vs. Machine Prototypes- Avoid smaller than 0603 or no exposed pins.
Avoid Custom Stick to industry standards unless you really need custom pads
THERMAL CONSIDERATIONS
• Calculate worst-case power dissipation
• Determine available cooling capability
• Select appropriate thermal resistance
• Verify junction temperature remains below derated maximum
• Consider component placement impact
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Assembly limits
COMPONENT COST
• Unit component cost
• Testing and qualification costs
• Manufacturing yield impact
• Field failure and warranty costs
• Redesign and obsolescence costs
ENGINEERING METHODS
Method Application Savings
Function Analysis Map component cost to functional value 10-30%
Cost Teardown Compare to competitive implementations 5-20%
Technology Alternative Analysis Evaluate different technical approaches 15-50%
Design-to-Cost Set cost targets before selection 20-40%
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Implementation Strategy:
• Define qualification requirements by component type
• Document required certifications and test reports
• Create supplier qualification checklist
• Develop incoming inspection protocols
• Establish waiver process for exceptions
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Component Selection Guide Shimi Cohen - All Rights Reserved
TRACEABILITY
COMPONENT DATA MANAGEMENT
Essential Component Documents
Implementation Approach
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CHANGE CONTROL
CHANGE DEFINITION
Change Categories
• Change identification/notification
• Impact assessment
• Verification testing requirements
• Implementation planning
• Documentation updates
• Validation and release
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COMPLIANCE DOCUMENTATION
Regulatory compliance requires thorough component documentation:
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APPLICATION-SPECIFIC
INDUSTRIAL COMPONENT SELECTION
Industrial applications demand specialized component selection considerations:
Implementation Strategy
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Component Selection Guide Shimi Cohen - All Rights Reserved
• Cost sensitivity
• Small form factor
• Aesthetic considerations
• Energy efficiency
• Moderate lifetime (2-5 years)
ICs Power consumption, package size Latest process nodes, smallest packages
Display Quality perception, power Optimize for visual impact vs. power
Implementation Strategy
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Component Selection Guide Shimi Cohen - All Rights Reserved
AUTOMOTIVE-GRADE COMPONENTS
Automotive applications require specialized component selection:
Implementation Strategy:
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DECISION-MAKING
COMPONENT SELECTION MATRIX
A component selection matrix
Matrix Structure:
• Components as rows
• Selection criteria as columns
• Weighting factors for each criterion
• Scoring scale (typically 1-5 or 1-10)
• Weighted sum for final comparison
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CASE-BY-CASE
RESISTOR SELECTION
Step-By-Step (Shunt Resistor)
When you need to select resistor for your design Do the following Steps:
Step [1] : Define Your Application
What is the role of the resistor, for this matter let's assume it is a shunt.
Step [2] : Find Value
Design Requirements:
Measuring 4A of 24V
Gain = 500.
Max Input = 3V
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Component Selection Guide Shimi Cohen - All Rights Reserved
INDUCTOR SELECTION
Step-By-Step (Buck Converter)
When you need to select inductor for your Power Supply (Voltage Regulator)
Step [1] : Define Your Application
In this case, the application is Switching Inductor.
Step [2] : Find Value
Design Requirements:
12V Input / 3.3V Output
Current Load : 1A Max
PWM Frequency = 1.2MHz
Required Ripple = 50mV out (on 3.3V)
Duty Cycle (D): D = Vout/Vin = 3.3V/12V = 0.275
Required Inductance: L = [(Vin - Vout) × D] / [f × ΔIL]
Estimated Current: Peak current = I Max + (ΔIL/2)
Solving the equations: For 50mV ripple, L ≈ 4.7μH
Step [3] : Select Size & Type
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Component Selection Guide Shimi Cohen - All Rights Reserved
DC-DC SELECTION
Step-By-Step (Buck- Boost Converter)
When you need to select inductor for your Power Supply (Voltage Regulator)
Step [1] : Define Your Application
In this case, Buck Boost Voltage Regulator
Step [2] : Find Options
Design Requirements:
8V – 14V Input / 12V Output
Current Load : 1A Max
Efficiency > 85%
Preferred Manufacturers : TI / Analog
LTC3111 (Analog Devices )
• Input Voltage Range: 2.5V to 15V (covers 8–14V input)
• Output Voltage Range: 2.5V to 15V (supports 12V output)
• Continuous Output Current: 1.5A
• Efficiency: Up to 95%
2. LM5118 (Texas Instruments)
• Input Voltage Range: 4V–75V (handles 8V–14V input).
• Output Current: Configurable via external MOSFETs (supports 1A+).
• Efficiency: Up to 90% in buck mode.
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ONLINE TOOLS
COMPONENT SERACH ENGINES
Tool Name Link
Octopart https://octopart.com/
SnapEDA https://www.snapeda.com/
Ultra Librarian https://www.ultralibrarian.com/
FindChips https://www.findchips.com/
Component Search https://componentsearchengine.com/
Digi-Key Selector https://www.digikey.com/products/en
Mouser Selector https://www.mouser.com/
PartSim BOM Tool https://www.partsim.com/tools/bom
PCB Footprint Wizard https://www.pcblibraries.com/pcb-footprint-wizard.aspx
SamacSys Search https://componentsearchengine.com/
Altium Part Search https://www.altium.com/part-search
DesignSpark https://www.rs-online.com/designspark/home
SIMULATION TOOLS
Tool Name Link
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AI ASSITANCE
AI CAN SAVE YOU TIME
AI Search For Components
AI Datasheet analysis
You found a candidate component, but you are not sure it meets all spec.
1. Download the datasheet of the desired component
2. Feed the AI with the PDF
3. Craft a Prompt with all requirement and constrains
4. Let AI analyze the datasheet file against the spec.
AI BOM Optimiztion
You have a BOM list of component but not sure regarding status or availability.
1. Prepare CSV or Excel with BOM
2. Feed the AI
3. Craft a prompt to check for Obsolete, NRND, Long Lead Time
4. AI will optimize the list and find alternatives based on your guidance
Extract BOM f rom Schematics
You need to get a BOM out of schematics and you have a PDF.
1. Save the schematics as PDF (you may need to divide it for resolution)
2. Feed the AI with all parts
3. Craft a Prompt to Arrange BOM list with values
4. Optimize the list and let it Look for real components
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