Intermittent ICT Test Failures From Worn Pogo Pins on a PCB Assembly Line

The problem showed up near the end of a small electronics build. The line was running fine, but our first-pass yield at ICT started dropping for one board revision. The failures looked random: open circuit on one connector pin, then a false short near a test pad, then the next board would pass. AOI looked clean, reflow profile was stable, and the same boards passed after re-seating in the…