Miniaturization Breakthrough: How Toward Fit 2,000 Channels on a 900cm² Board.
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This case study features a leading analog and mixed-signal IC provider specializing in power management ICs (PMICs). To validate these devices, high-power, high-density load boards are used, where relays handle critical switching and channel control. However, limited board space restricted relay count, forcing the use of an interface extension board to add channels. Conventional electromechanical relays also suffered from short lifetimes due to contact wear and a large footprint that limited channel density—adding unnecessary bulk and complexity to the test setup.
Customer Challenge: Ultra Density in a Highly Demanding Switching Application
PMIC validation demanded high-power, high-density load boards, but physical area on the main board limited relay count—forcing an interface extension board just to reach required channel count. The legacy approach used electromechanical relays (EMRs), which created two core engineering constraints: (1) short loaded lifetime from mechanical wear under frequent switching, increasing downtime and calibration/maintenance overhead, and (2) large relay footprint, directly capping channel density on the load board.
Toward's Solution: 1920 Channels, each handling 2A Signals
Toward replaced EMRs with VN Series reed relays and engineered the board for extreme integration without compromising test integrity. After migration, the customer packed 960 relays (~1,920 channels) into a 40 × 50 cm board footprint, eliminating bulky extension boards and increasing on-board channel density. Reed technology delivered significantly higher switching endurance for stable long-term operation. To prevent accuracy loss from EMI in this high-density/high-power switching environment, Toward used simulation-driven layout, optimized trace routing, and shielding strategies to maintain clean signal integrity and consistent isolation. Because the customer required SMT-only assembly (no through-hole), Toward also customized the VN package with gull-wing leads for direct surface-mount integration without sacrificing density or performance.
More on how Electrical Mechanical Relays Compare to Reed Relays
Reed relays typically achieve ~1,000,000 loaded operations (at resistive, rated conditions) versus ~100,000 for standard EMRs under comparable stress, primarily due to fundamental construction differences. Reed contacts are hermetically sealed in inert gas or vacuum, which prevents oxidation/contamination that degrades EMR contacts exposed to air. The switching element is also low-mass and directly magnetically actuated (no armatures/springs), reducing wear, bounce, and arc energy. In addition, rhodium/ruthenium contact plating improves resistance to arc erosion and helps limit contact-resistance drift over time. The simplified mechanism also enables smaller packages, supporting higher channel density for compact ATE/load-board layouts.
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Toward Technologies, Inc - A manufacturer of Solid State Relays, Reed Relays and MEMS Switches.
Located in Taiwan since 1988, Toward Technologies, Inc. is a relay supplier and manufacturer. Main products, including Opto-MOSFET Relays, Opto-SiC MOSFET Relays, Solid State Relays, Reed Relays, And RF MEMS Switches, etc.
Toward supplies relays to the world's semiconductor and automotive industries for over three decades and has long term long-term partnerships with OKITA Works based in Japan; Menlo Microsystems based in California; JEL Systems based in Japan and Teledyne Relays and Coax Switches based in California. Mainly serve the Semiconductor Testing, ATE, BMS (Battery Management Systems), industrial machinery and Electric Vehicle industries.
Toward has been offering customers high-quality Opto-MOSFET and Opto-SiC MOSFET relays since 1988, both with advanced technology and 37 years of experience, Toward ensures each customer's demands are met.