Printed circuit board assembly: Comparing the top 4 assembling methods!

 In this write-up, we are embarking on an enlightening adventure through the fascinating world of printed circuit board assembly. If you have dabbled in electronics or are simply curious about how your favorite gadgets are put together, you are in for a treat.

What is Printed Circuit Board Assembly?

Printed circuit boards are the unsung heroes of our electronic universe. They serve as the backbone of most electronic devices, providing a sturdy platform for connecting various electronic components. But what exactly is PCB assembly, you ask? Well, my friends, it’s the process where all the magical electronic components like resistors, capacitors, and microchips are mounted onto a PCB to create a functional electronic circuit.

Think of PCB assembly as a high-tech puzzle. Each component has its designated spot, and the challenge is making all the pieces fit perfectly to ensure the circuit works like a charm. This process is crucial because the efficiency and reliability of an electronic device depend heavily on how well its PCB is assembled.

Over the years, PCB assembly has evolved, with different methods emerging to meet the diverse needs of the electronics industry.

Today, we’ll break down the top four methods, examining their quirks, perks, and uses. Are you ready to jump in? Let's go!

1. Surface Mount Technology (SMT)

Surface Mount Technology, or SMT, is like the cool kid on the block when it comes to PCB assembly methods. It's sleek, efficient, and widely used. With SMT, components are mounted directly onto the surface of the PCB, eliminating the need for traditional wire leads.

The beauty of SMT lies in its space-saving design. Because components are placed directly on the board, there's room for more components on a single PCB. This method is perfect for creating compact, lightweight devices like smartphones, tablets, and wearables. Plus, SMT can handle high component densities, making it a favorite in industries demanding miniaturization.

However, SMT isn't without its challenges. The small size of components requires precision machinery and techniques, which can be costly for small-scale productions. Despite this, the benefits of SMT, such as improved performance and reduced electromagnetic interference, often outweigh the drawbacks.

2. Through-Hole Technology (THT)

Next up, we have Through-Hole Technology (THT), the classic method of PCB assembly. If SMT is the modern-day whiz kid, THT is the seasoned pro with years of experience. In THT, electronic components have leads that are inserted through holes on the PCB and soldered in place.

THT offers robust connections, making it ideal for applications requiring high mechanical strength and reliability. It's commonly used in military and aerospace applications, where durability is paramount. Additionally, THT is easier to handle manually, which is why it’s favored in prototyping and testing scenarios.

The trade-off with THT is its larger footprint compared to SMT. Components require more space on the PCB, which can be a limitation for compact devices. Still, for projects demanding ruggedness and dependability, THT remains a valuable choice.

3. Mixed Technology Assembly

Enter the best of both worlds - Mixed Technology Assembly. This method combines the strengths of both SMT and THT to create versatile PCB assemblies. By using SMT for components that require miniaturization and THT for components demanding durability, designers can optimize their PCBs for performance and reliability.

Mixed Technology Assembly is particularly handy in complex circuits where different components have varying requirements. It’s like having a toolbox with both a hammer and a screwdriver, ready to tackle any task thrown your way.

While mixed technology offers flexibility, it also presents challenges. The integration of both SMT and THT components requires careful planning and coordination, as well as specialized equipment. But for projects with diverse needs, this method provides a balanced solution.

4. Chip-on-Board (COB)

Last but not least, we have Chip-on-Board (COB) assembly. This lesser-known method involves mounting bare integrated circuits directly onto the PCB and covering them with a protective resin. COB is like the secret weapon in a PCB designer’s arsenal, often used in applications requiring high component density and minimal interference.

COB excels in situations where size and weight are critical factors. It's commonly used in LED lighting and display technologies where efficient heat dissipation is needed. Additionally, COB offers cost savings by eliminating the need for packaging individual chips.

However, COB assembly is less forgiving than other methods. Once components are encapsulated, rework becomes challenging, making it crucial to get things right the first time. Despite this, the benefits of COB, such as reduced parasitic capacitance and improved thermal performance, make it a compelling choice for specialized applications.

Final Thoughts

And there you have it, folks! We have taken a whirlwind tour of the top four printed circuit board assembly methods, each with its own unique charm and set of advantages. From the space-saving prowess of Surface Mount Technology to the rugged reliability of Through-Hole Technology, there's a method suited to every project and application.

PCB assembly is an intricate dance of precision and creativity, and choosing the right method is key to unlocking your project's potential. 

What are the important things to know about PCB assembly

The printed circuit board assembly or PCB assembly process is a complex sequence of steps that transforms a PCB design into a functional electronic product. It requires coordination between the PCB fabrication house, component suppliers, and the assembly factory to source all required materials.

The assembly process itself consists of soldering surface-mount components and through-hole components to the fabricated PCBs using solder paste printing, pick-and-place machines, wave soldering systems, and manual soldering. Each step introduces opportunities for defects if not executed properly.

That's why comprehensive testing and inspection are critical at multiple stages: after SMT assembly, after through-hole assembly, and as a final quality control check. Electrical tests validate connectivity and basic functionality, while automated optical inspection examines every joint for potential soldering defects.

When done correctly, this complete printed circuit board assembly process results in a high-quality and reliable circuit board assembly, ready for installation in an electronic product. Careful attention to quality controls and process validation is essential, as small flaws in assembly can lead to field failures down the line. The investment in diligent assembly practices pays dividends through increased product quality and reliability.

Popular methods for PCB assembly

SMT - Surface mount technology (SMT) is a method of attaching electronic components to printed circuit boards using a paste or glue. Surface mount technology has been widely used in the electronics industry since the 1970s, but it has recently become popular with hobbyists and DIYers who want to build their electronics projects without having to solder them.

The main advantage of surface mount technology is that it allows for a more compact and efficient design than traditional methods because there are fewer connections between components, which means less wasted space on the PCB or wasted time when trying to connect wires correctly.

THT - Through hole technology or THT is a method of component placement used in the manufacture of printed circuit boards (PCB).

In through hole technology, components are mounted on a printed circuit board by passing their leads through pre-drilled holes in the board and soldering them to the copper traces on the other side. The technique provides for easy assembly and repair of electronic devices but is less suitable for miniaturization than surface mount technology (SMT).

Reasons to outsource printed circuit board assembly

Because of the size and complexity of printed circuit boards (PCBs), it’s often more cost-effective to outsource their assembly. You can also save time by outsourcing the assembly instead of doing it in-house.

Outsourcing your PCB assembly can offer you numerous advantages:

Speed – It can take a long time to make a PCB, particularly if you need several layers. By outsourcing your PCB assembly, you can get it done quickly and have your product ready to ship in time for the market.

Cost – Outsourcing your circuit board assembly is often cheaper than doing it yourself. You won’t have to invest in expensive equipment or hire a team of engineers if you outsource the job instead. This will save money on both labor and materials costs.

Quality – When you outsource your circuit board assembly, quality control becomes much easier because everything will be handled by an experienced third party who knows how to handle sensitive electronic equipment with care. You won’t have to worry about any mistakes or damage during shipping and handling when outsourcing this job to an expert company that has been doing this for years!

Choosing the right company

There are many factors to consider when choosing the right printed circuit board assembly services. The first thing to consider is how complex your circuit boards are and whether you require surface mount technology or through hole technology. You also need to know about the materials that your circuit boards are made from and whether they can be used with solder reflow or wave soldering.

You should also think about how much volume you need, as this will determine how long it will take for your order to be manufactured, shipped, and delivered. It’s also important to consider the price of each type of service, as well as any additional costs associated with these services.

When choosing printed circuit board assembly services, you should look at all these factors so that you can choose which company offers the best value for money and quality service.

Electronic Manufacturing Services: 5 Benefits Explained!

The use of electronic manufacturing services or EMS is on the rise due to the proliferation of technology and rapid advancements in hardware, software, and software applications. With this growth in the industry, there is also a corresponding increase in demand for services related to electronic manufacturing.

What are the benefits of electronic manufacturingservices?

1. Reduced Costs

Partnering with an electronic manufacturing services provider can significantly reduce costs for electronics companies. EMS providers have access to an international labor pool, allowing them to take advantage of lower labor rates in certain regions. This results in lower overall manufacturing costs compared to utilizing a local, domestic workforce.

Additionally, by consolidating production in select global facilities, EMS providers benefit from economies of scale. Their purchasing power gives them leverage to negotiate better deals on components, raw materials, equipment, and other sourcing. These savings can be passed on to their customers. High-volume production also enables EMS providers to optimize manufacturing processes and amortize investments in automation technology over a wider production base.

EMS providers also have well-established global supply chains and logistics networks. This gives companies access to vetted, cost-effective component suppliers and freight providers worldwide. Utilizing an EMS provider essentially outsources supply chain management to specialists who can procure materials and ship products internationally in a cost-efficient manner.

2. Improved Quality

Partnering with an EMS provider means you can access specialized expertise, advanced technologies, and certified quality control processes. An EMS company has dedicated teams with deep domain knowledge and extensive experience designing, testing, and manufacturing electronic products.

Their expertise leads to higher-quality outputs. EMS providers implement rigorous quality control processes, such as ISO 9001 or AS9100 standards, at each stage of the production process. They perform extensive testing, inspection, verification, and validation to ensure products meet specifications before shipment. This level of stringent quality control is difficult for a company to replicate internally.

EMS providers also leverage state-of-the-art manufacturing technologies like automated assembly lines, advanced SMT equipment, and 3D inspection systems. This specialized equipment minimizes defects and produces consistent, high-quality results. With their expertise, processes, and technologies, EMS companies achieve near-zero defect rates that most manufacturers struggle to match in-house.

Partnering with an EMS provider gives you access to these capabilities, ensuring your products meet quality benchmarks and customer requirements. This expertise and quality focus also enable more rapid design iterations, allowing defects to be identified and eliminated earlier in the development process. The result is higher quality products shipped to your customers.

3. Faster Time-to-Market

Partnering with an EMS provider allows companies to get products to market much faster than setting up their manufacturing facility. There is no need to purchase equipment, hire operators, and set up a factory. By leveraging an EMS provider's existing infrastructure, companies can go from design to mass production very rapidly.

Many EMS providers offer rapid prototyping services to turn designs into physical prototypes in just days or weeks. They utilize the latest 3D printing and other technologies to iterate on prototypes quickly based on feedback. Once the design is finalized, the EMS provider can immediately start mass production using their equipment and assembly lines. This shrinks the product development cycle significantly.

Getting to market faster is critical for capturing market share before competitors. It also allows companies to start generating revenue sooner. EMS providers have the expertise and infrastructure to manufacture innovative new products rapidly without the overhead costs of setting up internal manufacturing. Their turnkey services enable bringing new products to market in months rather than years.

4. Flexibility

One of the key benefits of partnering with an EMS provider is flexibility. EMS providers have the infrastructure and processes in place to easily scale production up or down as needed. This enables companies to align manufacturing with fluctuations in market demand.

Rather than having excess internal capacity or being unable to meet demand spikes, outsourcing to an EMS allows production to flex according to real-time requirements. EMS providers specialize in managing volatility, making them far more adept than internal manufacturing operations.

In addition, EMS providers can readily accommodate engineering change orders and design modifications. Their expertise and range of capabilities make it simple to iterate on product designs without extensive retooling. This facilitates bringing enhanced and updated products to market faster.

The flexibility that EMS delivers is difficult for individual companies to match on their own. It enables organizations to be nimbler and more responsive to customers. The ability to scale production up and down and handle ongoing design changes is a major factor driving many companies to partner with EMS providers.

5. Focus on Core Competencies

One major benefit of partnering with an electronics manufacturing services provider is that it allows companies to focus their efforts on core competencies like design, marketing, and brand building rather than electronics assembly and manufacturing. Companies that design consumer electronics, industrial equipment, medical devices, aerospace systems, and automotive electronics can benefit from outsourcing manufacturing to an EMS partner.

Rather than investing capital and resources into operating their manufacturing facilities, companies can rely on EMS providers that specialize in manufacturing while they concentrate on their areas of expertise. Product designers and engineers at the company can devote more time to designing for manufacturability, reliability, and cost optimization rather than production processes. The marketing and sales teams can focus more on understanding customer needs, defining product requirements, product launches, and building the brand rather than manufacturing logistics.

Strategic outsourcing of electronics manufacturing to an EMS partner enables companies to play to their strengths. The EMS provider handles procurement, supply chain management, assembly, testing, order fulfillment, and other aspects of production. This allows the hiring company to fully leverage its core competencies in technology innovation and getting products to market. Outsourcing manufacturing allows nimble startups and established companies alike to accelerate growth and reduce costs. 

Methods of Printed Circuit Board Assembly

 Printed circuit boards, or PCBs, are used in a range of applications. They are made up of layers of copper foil and an insulator (plastic or glass) that separates the layers. Circuits are then etched into the copper to form connections between various components on the board, and the process is called printed circuit board assembly.

PCB assembly is a complex process that requires advanced equipment and trained personnel. In addition to this, the PCBs need to be tested in the final stage of production. This process can be very expensive for companies that do not have the resources or expertise to handle it internally.

PCB assembly services are very important to the electronics industry because they help manufacturers to meet their production deadlines. A service provider is a company that undertakes the process of assembling a printed circuit board into a finished product.

PCB assembly services matter because they help companies reduce production costs and increase the speed at which they produce electronic components. They also help to ensure that products are manufactured in line with customer specifications, which means that there is no room for error.

PCB assembly services can be provided by a variety of different companies and as such it is important that you choose an experienced supplier who can offer you the right solutions for your needs.

What are the methods of printed circuit board assembly?

1. SMT or surface mount technology

Surface mount technology or SMT is a method of soldering components to the surface of a printed circuit board. Since the 1980s, the trend has been for electronic manufacturers to decrease the size of all their products, from mainframes and microcomputers to mobile phones and digital watches. The dramatic reduction in size is due to advances in semiconductor processing and packaging technology. While integrated circuits were once assembled by hand, they are now almost always assembled using SMT techniques.

The SMT process involves placing components on both sides of a PCB, and then using heat and pressure to bond them directly to the board. This differs from through-hole component mounting, where leads are inserted into holes drilled through the PCB's laminate layers. In surface mount assembly, each component lead is placed through a hole in a solder mask (a protective coating on top of the laminate layers), then soldered to pads on opposite sides of the board by its leads or feet (pins).

2. THT or through hole technology

Through holes are components that have leads on the top of the PCB and are soldered to the solder pads on the bottom side.

Through hole technology is a method for printed circuit board assembly where components are inserted into holes in the board and soldered. Through hole technology is also known as THT.

The advantages of through hole technology are:

·         It is more reliable as it does not rely on solder joints.

·         It is easier to repair if a component fails.

·         It can be used with large components such as coils or relays.

Metal Core PCB Provider: 3 Factors to Select One!

A metal core PCB is a type of circuit board that has metal traces instead of copper. It is often used in high-voltage applications because it can withstand higher voltages than traditional PCBs. Some examples of products that use metal core PCBs include power supplies, lighting circuits, and heating systems.

MPCBs are made by printing conductive ink onto the base layer of glass fiber epoxy board. This ink contains metal particles that form a conductive path when they are exposed to heat. When the board is baked in an oven, these paths become permanently etched into the surface of the circuit board.

What are the benefits of using a Metal Core PCB?

The most obvious benefit is better signal integrity. Tin plating offers superior electrical properties compared to standard copper plating. It also reduces crosstalk by reducing impedance and impedance mismatches between layers. This leads to improved performance in high-frequency applications such as RFID tags or antennas where signal degradation is often caused by impedance mismatches between layers in the PCB structure. In addition, tin-plated layers make it possible for manufacturers to reduce their manufacturing costs by increasing circuit density without sacrificing performance or reliability.

Tin-plated layers also enable manufacturers to include multiple ground planes on one side of the board without causing interference with each other or having any adverse effects on adjacent components or traces because they all share the same ground plane which greatly reduces noise.

How to choose the right MCPCB provider?

When you are looking for a metal core PCB provider, there are some things to look for before you choose one. Here's how.

1. Find out if they have the equipment and experience

The number one thing you want to know is whether or not they have the equipment and experience necessary to make your design come to life. Not all companies have the same capabilities and not all companies have the same skill level. Some might be able to do it but they may not be able to do it as quickly as you need them too. Some might take longer because they don't have enough employees or maybe they just aren't that good at what they do yet. It's important that you find someone who has the right equipment and knows how to use it in order to get your job done right and on time.

2. Get references from previous customers

Asking for references from previous customers is always an important step in choosing an MCPCB company because it shows how many people like working with them and what kind of quality their work is like after all is said and done. If you are looking for someone who will do high-quality work but also charge a reasonable price then this can be an excellent way of finding those kinds of people.

3. Pricing

Last but not least, find out the average market price for your project and then find a provider who is willing to complete your project in that budget. However, do not compromise on quality for the sake of saving some bucks.

3 Advantages of Printed Circuit Board Design Services

Printed circuit boards or PCBs are the backbone of the modern electronics industry. PCBs are used in almost every electronic device you can think of, from cell phones to televisions, from radios to computers. A PCB is a flat board with copper traces on it that connect different components. Further, we will discuss the advantages of printed circuit board design services.

The components that make up a printed circuit board are:

The substrate: The substrate is the material used for making the board. It can be either plastic or fiberglass, but the most popular ones are FR-4 glass epoxy or Rogers 4350 Unimark 1 or 2.

The coating layer: This layer protects the copper traces from oxidation and corrosion damage by providing an insulating barrier between them and the atmosphere. The most common coating layers are ENIG (Electroless nickel immersion gold) and OSP (Organic surface protection).

The conductive tracks: These are made out of copper foil which is deposited onto the surface using screen printing methods. The tracks carry electricity between components and through the PCB itself.

Via holes: These holes connect one side of a track to another side of a track on the opposite side of the board through plated through holes (PTH).

What are printed circuit board design services?

Printed circuit boards (PCBs) are used for a wide range of electronic products and devices. They are one of the most common types of printed circuit assemblies (PCAs).

The design of a PCB includes several steps:

1. Designing the layout of components on the board. This is done using a computer-aided design (CAD) program, which allows you to arrange components and wires on your PC board.

2. Creating a list of components needed to build your circuit board. You can then purchase these components from an electronics supply company or online retailer.

3. Cut the boards out of sheet metal with a laser or water jet cutting tool so that they fit perfectly into their desired cases.

4. Testing the boards to ensure they work properly before sending them off to be mass-produced or sold as finished goods.

What are the advantages of PCB design services?

Printed circuit board (PCB) design services are an important part of the engineering process. PCBs are used in everything from medical equipment to the automotive industry. If you are planning on creating a PCB for your project, you should know that it is not as easy as just printing a few lines and connecting them. Many steps must be taken before you can even begin designing your board and these steps may vary depending on what type of project you are working on.

Here are some of the advantages that come with hiring professional printed circuit board design services:

1. Expertise

Professional PCB design services have years of experience in this field and know how to make sure that your project's needs are met accordingly. They understand exactly how to create boards that will work properly with the devices they connect to them as well as how to meet all safety standards set by government agencies around the world. You won't have any problems with these experts being able to design a board that meets all industry standards.

2. Cost Savings

Printed circuit boards (PCBs) are the backbone of most electronic equipment. They can be found in almost every piece of technology that you use on a day-to-day basis, and they are an essential part of the design process.

3. Time savings

You don't have to be a skilled PCB designer yourself because you can get the job done by professionals with years of experience in this field. This means that you can focus on your core competencies and leave the rest to them.

Metal core PCB advantages and design

Metal Core PCB (MCPCB) is a technology that has gained much popularity in recent years in the electronics industry. It is a type of printed circuit board that incorporates a base metal material, usually aluminum or copper. It is an ideal solution for applications where the printed circuit board itself may become too hot for the components and must be cooled. The heat is drawn away from the components and into the base material, which acts as a heat sink.

➜ Learn here Benefits of Metal Core PCB Fabrication

MCPCBs were first developed in the 1960s for use in military and aerospace applications where size, weight and reliability were critical factors. Due to their advantages over other materials, they are now also widely used in commercial products like automotive electronics, telecommunications and medical devices.

Today, it is widely used in various industries and has many advantages. The metal-based CCLs are widely used in the fields of LED lighting, power supply, semiconductor cooling and automotive electronics due to their special features.

They are made up of a dielectric layer, a base metal, and a copper layer. Metal core PCBs can be single-sided, double-sided, or multi-layer. The typical thickness of the metal substrate ranges from 0.5mm to 2mm, with the normal value being 1.0mm. The metal core provides a thermal path between the components and a heat sink that is used to dissipate the heat generated by power semiconductor devices such as LEDs, IGBTs and MOSFETs.

It is widely used in the LED lighting industry with the benefits of reduced weight, high power dissipation and improved thermal management.

The base metallic material in them can come in various alloy material types, such as:

Aluminum: This is the most commonly used metal core in MCPCBs. It works well with high-powered LEDs and is lightweight, durable and thermally conductive. Aluminum has a thermal conductivity rating of 170 W/mK.

Copper: Copper is also commonly used in them due to its durable nature and its high thermal conductivity rating of 401 W/mK. Copper also has higher stiffness than aluminum.

Why Use a Metal Core PCB?

Metal core circuit boards are used in applications with high power requirements and/or where significant heat is present. In these applications, the heat sink would be attached directly to the metal core of the PCB. These applications include power supplies, ballasts, inverters and other electronics that generate high levels of heat.

Advantages of Metal Core PCB

The main application advantage of metal core printed circuit boards is to improve heat dissipation for high power components. For example, LED lights often use aluminum as the base material to dissipate heat well.

Compared with normal FR4 (FR4 stands for fire retardant material number 4), MCPCB can conduct heat more efficiently and dissipate heat faster. The standard FR4 glass epoxy substrates have low thermal conductivity – 0.2 W/mK (watts per meter Kelvin). Whereas the thermal conductivity of an aluminum plate is around 200W/mK, which is 1000 times higher than FR4! Therefore, it can be used in products where high speed operation or heat accumulates.

Metal Core PCB design guidelines

Power dissipation: The most important factor for designing any metal core PCB is to estimate the power dissipation at each component location. This will help you decide which areas require extra copper thickness and thermal vias to provide better heat sinking for those areas. It is advisable to use professional software for this purpose as it helps designers quickly calculate the thermal resistance of components and package footprints.

PCB layout: The design of the PCB layout can affect the thermal performance of your circuit board significantly. Components that generate more heat should be positioned close to the edge.

Learn more

Everything You Must Know About PCBA or Printed Circuit Board Assembly