From controlling engine performance to enabling life-saving advanced driver-assistance systems (ADAS), the modern vehicle relies on a network of electronic systems that demand exceptional precision and reliability. At the heart of these systems are ball grid arrays (BGAs)—the tiny solder joints that provide the electrical and mechanical connections essential for smooth operation (see Figure 1). While they may be invisible to the casual observer, BGAs are integral to automotive technology.

Yet, as vehicles become more intelligent, interconnected, and electrified, the demands on BGAs grow. Extreme environments, continuous operation, and evolving functionality challenge their reliability at every turn. How can the automotive industry ensure these vital components remain robust under such relentless stress? This article dives into the challenges BGAs face and the innovations redefining their reliability