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Simulating this project is time-consuming. This example, with the datasets included, is available at: for download. 


When you fabricate designs using a milling machine, the milling bit must extend down through the PCB metal and into the dielectric below. Due to human error or small variations in the metal thickness, you will typically extend safely into the dielectric below. You now have a dielectric for your microstrip that is not truly a microstrip configuration. The metal is sitting up on a small layer of dielectric (the full thickness of the board) and then the remaining dielectric is thinner than the full dielectric. The situation is shown in the figure below.