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hitechpcb · 10 months ago

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What is PCB Assembly ?

PCB Assembly manufacturer - Hitech Circuits Co., Limited

It’s the step in the manufacturing process in which you populate a blank board with the electronic components needed to make it into a functional printed circuit board. It’s these components that make a board into the circuit that enables an electronic product to function. PCB assembly typically takes place via one of two processes:

1. Surface-mount technology

SMT: SMT stands for “Surface Mount Technology“. The SMT components are very small sizes and comes in various packages like 0201, 0402, 0603, 1608 packages for resistors and capacitors. Similarly for Integrated circuits ICs we have SOIC, TSSOP, QFP and BGA.

The SMT components assembly is very difficult for human hands and can be time taking process so it is mostly done by automated pick and place machine.

2. Through-hole manufacturing

THT: THT stands for “Through hole Technology”. The components with leads and wires, like resistors, capacitors, inductors, PDIP ICs, transformers, transistors, IGBTs, MOSFETS are example.

The component has to be inserted on one side of PCB and pulled by leg on other side and cut the leg and solder it. The THT components assembly is usually done by hand soldering and is relatively easy.

Printed Circuit Board Assembly Techniques

There are only two common PCBA techniques available for use by a PCB designer. The methods are:

1. Automated PCB Assembly Techniques

Generally, this technique employs the use of state of the art machines, which are fully automatic. For example, the surface mount components are worth positioning with the aid of an automated pick and place machine.

Again, reflow soldering is commonly for surface mount components usually done in a reflow oven. An automated solder stencil is also used to apply the solder paste on the PCB.

Finally, high tech inspection machines are used to confirm and check the quality of the PCBA. Some of which include: Automated optical inspection machine (AOI), X-ray inspection machines, etc.

Above all, due to the precise monitoring, control of soldering, no human input and versatile machines.

This technique ensures utmost efficiency, output consistencies, and limits defects.

2. Manual PCB Assembly Techniques

This method is favorite for use with through-hole parts, which needs manual placement on the board. Besides, with these through-hole parts, it’s advisable you use wave soldering. Note that in the through- hole assembly process, you need to place the components and electronics on the PCB.

After that, you use wave soldering to solder the leads. Typically, you will need an individual to insert a component into a marked PTH. Once done, transfer the PCB to the next station where the next person will be on standby tasked with fixing another part.

What are the Benefits of SMT PCB Assembly?

SMT assembly provides many benefits and some of them are as follows:

It can be used to incorporate small components.

In SMT, the components can be placed on both sides of the board.

It assures high component densities.

Fewer holes need to be drilled for surface mounting than through-hole.

It require low initial costs and time for setting up the mass production.

SMT is the simpler and faster-automated assembly when compared to through-hole.

Errors regarding the component placement can be easily rectified.

Surface mount PCBs feature strong joints, which can easily withstand vibrations.

What are the techniques used in Surface Mount Technology?

There are several techniques for the reflow process. After applying the solder paste or a flux mixture on the board and after placing the components, the boards are conveyed to a reflow soldering oven. The techniques used for reflowing soldering include infrared lamps, hot gas convection, fluorocarbon liquids with a high boiling point, and so on.

What are the different testing methods used in SMT PCB Assembly?

Hitech Circuits as the PCB assembly manufacturer, we perform the following testing and inspection to ensure the quality of surface mount PCBs.

Automated Optical Inspection (AOI): This is performed before and after the soldering to identify the component placement, presence, and solder quality.

X-ray Testing: In this type of testing, the operator relies on the X-ray images of the PCB to check the solder joints and lead-less components such as Quad Flat Packs and ball grid arrays, which are generally not visible to naked eyes.

In-Circuit Testing (ICT): This method is used to detect manufacturing defects by testing the electrical properties in the SMT Assembly.

What type of files or documents should I send for SMT PCB Assembly?

Gerber Files: The file contains all details of physical board layers including solder masks, copper layers, drill data, legends, and so on.

Bill of Materials (BOM): This contains information on the list of items needed for the PCB manufacturing and the instructions of manufacturing.

Pick and Place File: This file contains information on all components to be used in the PCB design and their rotation and X-Y coordinates.

The whole process of PCB Assembly

1. Bare board loader machine

The first step in the PCB assembly is to arrange the bare boards on the rack, and the machine will automatically send the boards one by one into the SMT assembly line.

2. Printing solder paste

When PCB on the SMT production line, firstly, we have to print solder paste on it, and the solder paste will be printed on the pads of the PCB. These solder pastes will be melt and solder the electronic parts to the circuit board when it passes through the high-temperature reflow oven.

In addition, when testing new products, some people will use film board/adhesive cardboard instead of solder paste, which can increase the efficiency for adjusting the SMT machines.

3. Solder paste inspection machine(SPI)

Since the quality of solder paste printing is related to the quality of welding of subsequent parts, some SMT factories will use optical machine to check the quality of solder paste after printed the solder paste in order to ensure stable quality. If there any poorly printed solder paste board, we will wash off the solder paste on it and reprint, or remove the excess solder paste if there is redundant solder paste on it.

4. High speed SMT machine

Usually, we will put some small electronic parts (such as small resistors, capacitors, and inductors) to be printed on the circuit board first, and these parts will be slightly stuck by the solder paste just printed on the circuit board, so even if the speed of printing is very fast and the parts on the board will not fall away. But large parts are not suitable for use in such high speed SMT machines, which will slow down the speed of small parts assembly. And the parts will be shifted from the original position due to the rapid movement of the board.

5. Universal SMT machine

Universal SMT machine is also known as "slow machine", it will be assembled some large electronic components, such as BGA IC, connectors, etc., these parts need more accurate positions, so the alignment is very important. Use a camera to take a picture to confirm the position of the parts, so the speed is much slower than High speed SMT machine we taked before. Due to the size of the components here, not all of them are packed in tape and reel, and some may be packed in trays or tubes. But if you want the SMT machine to recognize the trays or tube-shaped packaging materials, you must configure an additional machine.

Generally, traditional SMT machines are using the principle of suction to move electronic parts, and in order to place the parts successfully, and there must be the flat surface on these electronic components for the suction nozzle of the SMT machine to absorb. However, for some electronic parts don’t have a flat surface for these machines, and it is necessary to order special nozzles for these special-shaped parts, or add a flat tape on the parts, or wear a flat cap for thees electronic parts.

6. Manual parts or visual inspection

After assembled all parts by the high speed SMT machine or Universal SMT machine and before going through the high-temperature reflow oven, and we will set up a visual inspection station here and to pick out the deviation parts or missing components boards etc., because we have to use a soldering iron to repair if there are still defectives boards after passing the high-temperature oven, which will affect the quality of the product and will also increase the cost. in addition, for some larger electronic parts or traditional DIP parts or some special reasons cannot be processed by the SMT machine before, they will be manually placed on pcb here.

7. Reflow oven

The purpose of reflow oven is to melt the solder paste and form a non-metallic compound on the component feet and the circuit board, that means to solder electronic components on the circuit board. The temperature rise and fall curves often affect the soldering quality of the entire circuit board. According to the characteristics of the solder materials, usually the reflow oven will set the preheating zone, soaking zone, reflow zone, and cooling zone to achieve the best soldering effect.

For example, the melting point for SAC305 solder paste with lead-free is about 217°C, which means that the temperature of the reflow oven must be higher than the melting points to remelt the solder paste. What's more, the maximum temperature in the reflow furnace should not exceed 250°C, otherwise many parts will be deformed or melted because they cannot withstand such a high temperature.

Basically, after the pcb passed through the reflow oven, the assembly for the entire circuit board is almost complete. If there are hand-soldered parts, we need to transfer to DIP process, and then we have to check the quality after reflow oven by QC department.

8. Automatic optical inspection(AOI)

The main purpose of setting up AOI is because some high density boards can’t be process the following ICT test, so we used AOI inspection to replace it. But even using AOI inspections, there still have the blind spots for such checking, for example, the solder pads under the components cannot be checked by AOI. At present, it can only check whether the parts have side standing issue, missing parts, displacement, polarity direction, solder bridges, lack of soldering etc., but cannot checking the BGA solderability, resistance value, capacitance value, inductance value and other components quality, so far AOI inspection can’t completely replace ICT test.

Therefore, there is still some risk if only AOI inspection is used to replace ICT testing, but ICT test is also not 100% make sure the good quality, we suggest these two ways can be combined with together to make sure the good quality.

9. PCB unloader machine

After the board is fully assembled, it will be retracted to the unloder machine, which has been designed to allow the SMT machine to automatically pick and place the board without damaging the quality for PCB.

10. Visual inspection for finished products

Normally there will be a visual inspection area in our SMT production line whether there is an AOI station or not, and it will help to check if there are any defectives after completed assembled the pcbs. If there is an AOI station, it can reduce the visual inspection worker on our SMT line, and to reduce the potential cost, and because it is still necessary to check some places that cannot be judged by AOI, many SMT factories will provide the mainly visual inspection templates at this station, which is convenient for visual inspection worker to inspect some key parts and polarity for components.

11. DIP process

DIP process is a very important process in the whole PCBA processing, and the processing quality will directly affect the functional for PCBA boards, so it is necessary to pay more attention to the DIP process. There are many preliminary preparations for DIP process. The basic process is to re-process the electronic components first, like to cut the extra pins for some DIP components, our staff received the components according to the BOM list, and will check whether the material part numbers and specifications are correct or not, and performs pre-production pre-processing according to the PCBA samples. The steps are: Use various related equipment (automatic capacitor pins cutting machine, jumper bending machine, diode and triode automatic forming machine, automatic belt forming machine and other machines) for processing.

12. ICT test

Printed Circuit board open/short circuit test (ICT, In-Circuit Test), The purpose of ICT test is mainly to test whether the components and circuits on the printed circuit board are open or short issues. It can also measure the basic characteristics of most components, such as resistance, capacitance, and inductance values to judge whether the functions of these parts are damaged, wrong parts or missing parts etc. after passing through the high-temperature reflow oven.

ICT test machines are divided into advanced and basic machines. The basic ICT test machines are generally called MDA (Manufacturing Defect Analyzer). It’s just to measure the basic characteristics of electronic components and judge open and short circuits issue we talked above.

In addition to all the functions of the basic ICT test machines, for advanced ICT test machine can also test the whole PCBA by using power, start to testing the PCBA boards by setting the program in the test machine. The advantage is that it can simulate the function of the printed circuit board under the actual power-on condition, this test can partly replace the following functional test machine (Function Test). But the cost for the test fixture of this advanced ICT test can probably buy a car, it’s too expensive and we suggest it can be used in mass production products.

13. PCBA function test

Functional testing is to make up for the ICT test, because ICT only tests the open and short circuits on the the PCBA board, and other functions such as BGA and other fuctions are not tested, so it is necessary to use a functional testing machine to test all functions on the whole PCBA board.

14. Cutting board (assembly board de-panel)

Normally, printed circuit boards will be produced in panel, and it will be assembled to increase the efficiency of SMT production. It means several single boards in one panel, such as two-in-one, four-in-one etc. After finished all the pcb assembly��process, it needs to be cut into single boards, and for some printed circuit boards with only single boards also need to cut off some redundant board edges.

There are several ways to cut the printed circuit board. You can design the V-cut using the blade cutting machine (Scoring) or directly manually break off the board (not recommended). For more high density circuit boards, it will be used the professional splitting machine or the router to split the board without any damage the electronic components and printed circuit boards, but the cost and working hours will be a little longer.

Why Choose Hitech Circuits PCB Assembly Manufacturer for Your PCB Assembly Projects?

There are several PCB manufacturers specializing in PCB assemblyservices. However, Hitech Circuits PCB Assembly stands out owing to the following:

Assistance in Material Procurement:

Technically, in PCB assembly services, the quality of parts is the responsibility of the OEM; however, we ease your job by assisting you to make the right selection. We can help you procure all your parts of the same type own a single part number, thanks to our supply chain and vendor network as well as experience. This saves time and cost that goes in ordering single parts as you plan.

Testing procedures:

We are very focused on quality and thus implement stringent testing procedures at each stage of the assembly and after completion.

Fast Turnaround Times:

Our well-equipped facility and the right tools enable us to complete your requirements well before time, and without compromising on the quality or functioning of the PCBs. For simple designs we revert in 24 to 48 hours.

Cost Effectiveness:

While PCB assembly is a cost-effective alternative, we go a step further and assure that the parts you list are of a good quality and suitable for your requirement. Also, you can control the part flow and replenish them as needed. This eliminates the need to buy extra stock and store it.

Quick Quote:

We offer a quick quote based on your BOM. All you need is a detailed BOM, Gerber files, your application requirement sheet, and quantity.

We’re not one to stand still, which is why we use the latest equipment and the finest minds to create your PCB projects. We’re constantly keeping our finger on the pulse of the latest trends. And as a result, we know how to deliver the highest standards of PCB assembly to meet all your requirements.

Our dedicated, friendly customer service team also means that we support you every step of the way. Offering our expert guidance to ensure a complete PCB project that you’re happy with.

No matter what your printed circuit board assemblyneeds are, we always aim to deliver efficient, dependable solutions. For more information about our services, do not hesitate to get in touch with us today for a no-obligation quote

#pcb assembly #pcb manufacturer #pcb fabrication #pcba factory

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jalina268 · 1 year ago

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Array is to make automated assembly faster and less expensive.Running an array of boards through a pick-and-place machine is far more efficient than sending them through one at a time. Arrays are allowed the addition of tooling rails, tooling holes, fiducials,to help assembler

#PCB panel parameter #Array #Tooling Rail #Fiducials #Tooling Holes #Scoring #Break-rout tabs #X Outs #Stencils

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mfgepsilonelectronic · 8 days ago

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5 Benefits of Using a Stencil Printing Service

Stencil printing service is one of the most critical services of the whole PCB manufacturing process as it involves precise and efficient deposition of solder paste on the circuit boards. This technique makes it effective when it comes to the manufacturing of accurate and high-performance PCBs that are increasingly in high demand within today’s electronics market.

Accuracy and productivity are paramount in current PCB fabrication to avoid mistakes, cutting costs, and ensure product quality. When a manufacturer employs the stencil printing service, issues such as accuracy and efficiency are addressed besides addressing the necessities of complex designs and bulk production.

Improved Accuracy and Precision

Stencil printing service Providers are a critical component of the process since they determine how solder paste is applied on PCBs. It provides high-quality stencils and performs accurate paste printing with optimum paste volume deposition on each pad and fine-pitch components too.

Compared to manual soldering, this method minimizes any possibility oferrors that may include poor distribution of paste or misalignment of components. However, stencil printing provides a better level of accuracy than the other methods needed for proper PCB performance.

Also, it is effective especially if the PCB layout is complex, and using a professional stencil printing service is most useful to guarantee that there will be uniformity in the result. It can handle high density layouts or complicated patterns offering the level of precision required to meet today’s manufacturing requirements as a reliable to get perfect PCBs.

Enhanced Production Efficiency

As the electronics industry tightens up its screws on product intending to reduce the manufacturing time of PCB, manufacturers have no option but to look at ways of doing so. A stencil printing service helps in the solder paste deployment process to take a shorter time when applied in mass production. Compared to conventional methods of stencil printing, the use of a machine is less likely to produce inconsistent results in addition to reducing the time-consuming process.

This approach helps in increasing the rate of production so as to assemble more products while maintaining quality. However, it is especially valuable when there is a tight deadline on the project and you need to work with large quantities of print materials. Using professional stencil printing services, manufacturers can accelerate production and stay competitive within the industry.

Cost-Effectiveness

Employing a stencil printing service is a very effective way to reduce cost and have better control in creating the solder paste deposit on several printed circuit boards. It also reduces wastage of materials and helps to avoid an error which in turn leads to reduction of costs of production.

Volume production show that solders paste application should be consistent and accurate to minimize or reduce on quality problems, rework and field failure. Epsilon Electronics’ stencil printing service provides the highest degree of reliability, optimizing processes and maintaining quality for all PCBs.

Consistency and Reliability

A stencil printing service provides the correct and uniform solder paste deposition on each layer of the PCB regardless of its density or scale. This aspect eliminates the issues normally tied to handmade processes, guaranteeing unmatched quality, including in large-scale production. To add to this, Epsilon Electronics has gone a notch higher to provide a sophisticated stencils printing in order to offer a perfect solution for each project.

Support for Complex PCB Designs

A stencil printing service is needed to be able to handle the needs of complicated PCB designs at the present time. Through the use of solder paste deposition, stencil printing enables the correct implementation of intricate designs and high-density mesh patterns. This is particularly important in electronics manufacturing for components like SMDs, which are more intricate and require extreme precision.

With stencil printing, there is a possibility of cost-effective and innovative PCBs that suit the current demanding sectors like telecommunications, healthcare, and automotive industries. This not only facilitates the design flexibility but also improves the quality control at a higher level so that businesses can survive and excel in the competitive world.

Choose Epsilon Electronics for Stencil Printing Services

The advantages of getting your product through a stencil printing service include accuracy, efficiency, cost savings, quality control, and design complications of PCBs. Such benefits enable stencil printing to be considered as a crucial part of generating high-quality PCBs.

Epsilon Electronics is known for their high level of accuracy, dependability, and cost effectiveness that guarantees quality on your projects. For any complex stencils or for large orders we provide a custom stencil printing service making sure quality is consistent throughout.

#Stencil Printing Services

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circuitcardassembly · 9 days ago

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Comprehensive Guide to SMT Circuit Board, Surface Mount PCB, and PCB Assembly Manufacturing

Surface Mount Technology (SMT) is at the heart of present day hardware, powering everything from smart phones to mechanical apparatus. In this direct, we investigate the basics of SMT Circuit Boards, Surface Mount PCBs, SMT PCB Boards, and the PCB assembly Manufacturing prepare. This comprehensive see at SMT highlights its focal points, the Manufacturing prepare, and its applications over different industries.

What is an SMT Circuit Board?

An SMT Circuit Board alludes to a printed circuit board (PCB) on which components are mounted specifically onto the surface, utilizing Surface Mount Technology. This strategy permits for a more compact and effective board plan, making it perfect for advanced gadgets. Not at all like conventional through-hole strategies, SMT does not require boring, permitting for quicker, more exact assembly.

Understanding Surface Mount PCB and SMT PCB Board

A Surface Mount PCB is a PCB particularly planned to bolster surface-mounted components. Utilizing SMT, producers put components on the PCB’s surface, permitting for a thick and proficient plan. This Technology is fundamental in miniaturized electronic gadgets, as it spares space without compromising performance.

The SMT PCB Board is commonly utilized over businesses, from customer gadgets to aviation Technology. Due to its compact plan, it is perfect for high-performance applications that require accuracy and durability.

Key Preferences of Surface Mount Technology in PCB Assembly

Surface Mount Technology offers various benefits that make it crucial in PCB Assembly manufacturing:

1. Compact Design

SMT permits for littler and lighter Boards, fundamental in today’s miniaturized gadgets, from smart phones to restorative equipment.

2. High-Speed Manufacturing

With computerized machines putting components, SMT streamlines the generation handle, empowering speedier Manufacturing speeds.

3. Improved Execution and Reliability

SMT components are less likely to involvement physical stretch, giving superior unwavering quality in high-vibration environments.

4. Reduced Cost

SMT assembly requires less materials and less labor, decreasing in general Manufacturing costs.

The Handle of PCB Assembly Manufacturing Utilizing SMT

PCB Assembly Manufacturing utilizing SMT includes a few exact and profoundly controlled steps:

1. Solder Paste ApplicationA stencil is utilized to apply patch glue to the zones where components will be put. This glue serves as the “Paste” for surface-mounted components.

2. Component Placement

Automated machines put each component precisely onto the patch paste-covered zones. This step is vital for adjusting components precisely.

3. Reflow Soldering

The PCB is at that point warmed in a reflow stove, softening the patch glue and making solid, steady bonds between components and the board.

4. Inspection and Quality Control

Once patched, the SMT PCB experiences thorough review. Strategies like Automated Optical Inspection (AOI) and X-ray assessment distinguish surrenders to guarantee ideal performance.5. Testing

Finally, utilitarian testing is conducted to affirm that the board works as planning. Imperfect Boards are repaired or disposed of to keep up tall quality.

Applications of SMT Circuit Boards and Surface Mount PCBs

Due to their compact estimate and tall unwavering quality, SMT Circuit Boards and Surface Mount PCBs are utilized in a wide extend of applications:

• Consumer Gadgets such as smart phones, portable workstations, and wearable's.

• Automotive Hardware for motor control units, infotainment, and security systems.

• Medical Gadgets counting symptomatic gear and convenient wellbeing monitors.

• Telecommunications for arrange foundation, switches, and flag preparing devices.

• Aerospace and Protection where solidness and execution beneath extraordinary conditions are critical.

Choosing a Solid PCB Assembly Manufacturer

Selecting the right PCB assembly manufacturer is significant for accomplishing quality and unwavering quality in electronic items. A dependable producer provides:

• Expertise in SMT Assembly

Look for producers experienced in SMT, guaranteeing they utilize the most recent Technology and high-quality materials.

• Advanced Testing and Quality Assurance

The producer ought to have strong quality control forms to guarantee each board meets strict standards.

• Custom Solutions

Choose a supplier competent of customizing PCB plans to fit your particular venture requirements.

Final Considerations on SMT Circuit Boards and PCB Assembly Manufacturing

SMT Circuit Boards and Surface Mount PCBs are essential in advanced electronic gadgets. Their compact, proficient plan permits for tall execution in a assortment of applications. Whether you're creating shopper hardware or mechanical hardware, choosing high-quality SMT PCB Assembly can altogether affect the unwavering quality and victory of your item.

#SMT Circuit Board #Surface Mount PCB #SMT PCB Board #PCB Assembly Manufacturing

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