Preventing ESD Damage in Electronic Products: Best Practices for Reliability

Catastrophic Failure

Sometimes ESD damage shows up right away. A single spark can severely damage a chip or circuit, rendering the product unusable. In most cases, the device is beyond repair.

Latent Defects

In many situations, the damage isn't visible at first. The product may seem fine when it leaves the factory, but the weakened part eventually breaks down. Such a hidden failure is often the most frustrating because it causes problems weeks or months later, usually after the customer has already started using the product.

Parametric Shifts

ESD can also weaken a product without stopping it completely. The device still works, but its performance slowly drops. It may become less reliable, lose efficiency, or behave in unexpected ways over time.

Real-World Examples

ESD can affect various industries. For example, Phone chips may fail after a short period of use. Semiconductor wafers can be ruined during production. Even medical devices can stop working when reliability is most critical. All of these problems begin with a spark that is too small for the human eye to see.

The result is often reduced reliability and costly product returns. For businesses, it can mean higher warranty expenses and frustrated customers who lose confidence in the brand.

Static Buildup on People

One of the most significant sources of static electricity is the human body. Simply walking across a floor or touching a chair can build up a charge. When that charge is released into a circuit or chip, it can cause severe damage.

Friction from Materials

Everyday materials like plastic packaging, clothing, or even a work surface can create static through friction. When parts come into contact with these materials, the risk of discharge increases.

Low Humidity

Dry air makes static buildup worse. In facilities where humidity is too low, charges form more easily and stay on surfaces longer, making electronics more vulnerable.

Improper Handling

If workers handle parts without grounding themselves, ESD is likely to occur. A simple touch is enough to pass along a harmful charge to a sensitive component.

Poor Storage and Transport

Storing or shipping components in regular plastic bags or foam can also lead to problems. Without protective packaging, static charge can collect on products during storage or transport and discharge when they are handled, often causing damage.

Workplace Controls

The work environment is the first line of defence against static discharge. A well-prepared facility reduces the chances of charges building up and harming sensitive parts.

• Use antistatic flooring and work surfaces to keep static from accumulating.
• Maintain indoor humidity between 40 and 60 per cent to limit static buildup in the air.
• Equip workstations and chairs with ESD-safe materials to provide consistent protection.

Personal Controls

Since people are the most common source of static, personal protection is essential. With the right equipment and training, workers can safely handle even the most delicate components.

• Wear wrist straps and heel grounders to stay continuously grounded.
• Use ESD-safe clothing, shoes, and gloves to minimise static from fabrics and skin contact.
• Provide regular training sessions so workers understand the risks and follow best practices.

Product and Packaging Controls

Protecting parts doesn't stop at the workstation. Proper storage and packaging keep products safe while they move through the supply chain.

• Store and ship items in shielding bags, conductive foam, or other ESD-safe containers.
• Avoid regular plastic, bubble wrap, or Styrofoam, which can generate static charges.
• Add clear ESD labels to packaging so everyone in the chain knows to handle items carefully.

Compliance and Audits

Regular audits help confirm that ESD practices follow international guidelines and keep operations consistent.

• Follow recognised standards such as ANSI/ESD S20.20 and IEC 61340.
• Schedule routine ESD audits to identify weaknesses in your setup.
• Use audit results to update training and improve workplace practices.

Continuous Monitoring

Workstations and operators should be monitored in real time to prevent lapses in protection.

• Install continuous monitoring systems for wrist straps and grounding points.
• Track workstation performance to ensure safety equipment is always working.
• Alert systems can notify staff immediately if protection fails.

Equipment Checks and Records

Regular testing of tools and equipment ensures long-term reliability and prevents unnoticed failures.

• Use surface resistance meters on a routine basis.
• Keep logs of all ESD checks for traceability and quality control.
• Review records often to spot patterns and prevent recurring issues.

Circuit-Level Protection

Small components can act as shields against sudden surges of electricity.

• Include built-in ESD protection diodes in circuit design.
• Add TVS (Transient Voltage Suppression) diodes and filters where necessary.
• Use shielding materials to redirect harmful charges away from sensitive parts.

PCB Layout Practices

The way a circuit board is designed also affects its resistance to ESD.

• Keep high-voltage and sensitive areas well separated on the board.
• Use ground planes to disperse unexpected charges safely.
• Minimise trace lengths that could act as pathways for static discharge.

Balancing Cost and Reliability

Stronger ESD protection often incurs additional costs, but it pays off by reducing failures.

• Evaluate the risk of failure against the added cost of protective components.
• Use protection in critical areas where failure would be most damaging.
• Invest in reliability early to save on warranty claims and customer support later.

Better Product Reliability

When products are protected from ESD, they last longer and perform as expected.

• Fewer breakdowns mean fewer customer complaints.
• Reduced returns save time and money for both the manufacturer and the retailer.
• Long-lasting products strengthen customer loyalty.

Lower Costs

Every failure has a price. Preventing ESD helps keep those costs under control.

• Fewer warranty claims reduce after-sales expenses.
• Less rework and scrap lowers production costs.
• Strong prevention leads to more efficient operations overall.

Stronger Brand Reputation

A reliable product builds trust and credibility in the market.

• Customers are more likely to recommend brands they trust.
• Consistent quality improves a company's image in competitive industries.
• A reputation for reliability opens doors to new partnerships.

Easier Global Expansion

International markets often require proof of compliance with ESD standards.

• Meeting standards such as ANSI/ESD S20.20 makes exports smoother.
• Compliance reduces the risks of rejection in overseas markets.
• Certification builds confidence with international clients.