What are the Advantages of Custom Cable Assembly to meet your bespoke needs?

By | Date posted: | Last updated: April 19, 2023
custom-cable-assembly

An off-the-shelf cable harness assembly may look like a convenient, easy to use option. The fact, however, remains that high quality cables that are custom made to suit your bespoke needs can go a long way in meeting the needs of your project accurately.

Here are the many advantages that are offered by custom cable assemblies:

Adaptability

The biggest advantage of custom cable assemblies is the fact that they are manufactured to meet your exact requirements. You need not worry about aspects such as cable length or quality. Not only are you buying exactly what your project needs, what you also get is custom installation to suit your requirements. Accuracy and enhanced functionality are therefore a given! Not only are standard cables hard to manage, they also occupy a lot of space. With custom cables you need not worry about the organization of wires or the space that they tend to consume.

Prototyping

A sizeable advantage that custom cable assembly offers is that of effective prototyping. Prototyping offers you a very clear insight on the design changes etc. that you need to make in order to ensure success of your project. This isn’t possible with standard cables as they will not do justice to your unique requirements.

Quick turnaround time

Quick time to market is the requirement for any project. However, connecting different devices with standard cables is a task that is extremely time consuming. With a custom cable assembly manufacturer, what you have is someone to share your load. What it means is a quick turnaround time and enhanced competitiveness.

Scaling up production

Custom cables are an important component that helps upgrade your production and enables you to achieve your project completion goals.

Quality

In a competitive marketplace, the one thing that you cannot compromise on is project quality. This is one thing that you can ensure with custom cables. Essentially with cables customized to your requirements you can in-build accuracy into your project. What that means is that you do not have to deal with any performance issues later. Additionally, if you opt for a turnkey service provider you also ensure that all the work is done under one roof, thereby taking away any issues that emerge on account of any third parties.

Bespoke features

With custom cables not only are you able to control aspects such as cable length and quality, you also have full control over parameters such as cable protection, jacket color, insulation and more. The fact that when you take delivery, you have already tested it for your specific application is an added perk. Irrespective of how complicated or specialized your needs are a custom fit assembly can match the cable performance to your exact demands.

Cost Saving

While typically custom assemblies are associated with high costs, the fact is that these costs are only upfront. In the long run, you tend to ensure that the cost is more than recovered as you do not have to pay for costly errors. Additionally, you do not waste money on hit and trial, paying for cables that do not meet your specifications. Instead with proper testing of custom cable assemblies you are sure to get working projects. You also do not need to retrofit the assembly to your application and that also results in saving of time.

Also checkout: Cable Assembly Manufacturing Cost

Branding Efficacy

The role of branding in today’s environment cannot be overstated. Branding tends to percolate to several aspects including the product that needs to stick to certain color scheme and aesthetics. With custom cables it is easily possible to stick to your color scheme and overall sense of professionalism.

Eco-friendly

Last but definitely not the least, custom cable setups not only help you remain organized, they also help reduce excessive wastage in the manufacturing process. That you are doing your bit to save the environment, is therefore a given!

To sum up
With the above advantages, it is about time you chose custom cables for your project. From improved efficiency to cost and time saving, there are enough and more reasons that will ratify your decision. Time spent in choosing your custom cable assembly manufacturer will stand you in good stead to ensure the efficacy of your project.

Technotronix designs custom cable assembly for automatic systems, HVAC controls computers, electronic appliances, and defense equipment. We prepare the cable harnessing to meet every industrial requirement and maintain the standard of wire harness cables. Cable assembly from Technotronix; will give you ample solutions to install any electronic appliance in your industry that can reduce cables’ count and provide the best cable solutions. If you have any requirements related to cable harness, wire harness, custom cable assemblies or more, feel free to request a quick cable harness quote.

Top Design Guidelines for RF and Microwave PCB Assembly!

By | Date posted: | Last updated: February 15, 2023
RF and Microwave Design

What comes to mind when thinking of PCB designs? When talking about PCB Designs, one of the most reliable ones can be RF and Microwave PCB assembly. They have the incredible ability to feature higher frequencies, which makes them better than the other boards. Thus, the use Of Microwave and RF circuit boards have increased.

These PCBs’ designs used to be costly, so only Aerospace and Military industries used them.
However, things have changed now. Nowadays, Microwave and RF PCB assemblies are being used in several products. Such products may include Wireless networks, cell phones, Satellite broadcasters, and many other handheld wireless devices. They are also found in Various professional and commercial products, including communicational, medical, industrial, and many other applications/Products of various fields.

Even though such PCBs’ functioning is incredible (as they can capture higher frequencies), it is quite challenging to design their assemblies. The higher the frequency catching capability, the higher the difficulty in designing will be. However, that cannot stop you from designing such PCB since they can be beneficial compared to are other digital and analog circuits.
Let’s get to the details of assembling RF and Microwave PCB.

Describing Microwave and RF circuit boards

We can consider microwave and radiofrequency circuit boards as those PCBs that can operate on high frequencies. They contain those components through which RF or microwave signals are carried and usually work on signals ranging from megahertz to gigahertz frequency. It means that they can capture frequencies ranging from medium to too high. This is why they have excessively used various products to get communication signals in almost most things.
If someone needs to know the guidelines of assembling RF and Microwave PCBs, they should know that the basic knowledge of microwave PCB and RF PCB Is necessary. Assembly of RF and microwave PCB requires specific materials, parts, and technology. The materials that you are assembling in such PCBs need to be of high quality as well.

Such Printed circuit boards differ from digital and analog circuit boards. It is because Microwave and RF circuit boards have considerably high-frequency analog signals. Such signals can be at any level of voltage and current starting from minimum to maximum ranges. You wouldn’t see such functions in regular analog or digital circuits. Let’s now discuss the designing basics of Microwave and RF PCBs.

Designing guidelines of RF/Microwave Circuit Board Assembly

During the RF/Microwave PCB designing process, there are several things to consider and specific guidelines to follow. It is because there are various difficulties in the designing and assembly of such PCBs.

Thus, make sure that you follow certain guidelines and take into consideration specific problems that are as follows:

  • RF and Microwave have signals that are highly sensitive to noise. Thus, during the designing of RF and Microwave Frequency signals, there are certain things that a designer needs to keep in mind and understand the noise sensitivity of RF and microwave frequency signals. It is because such problems can create functional problems and errors in the PCB.
  • During the designing process, one should Remember to keep most of the parts (that are required to assemble the PCB) separate. It is because loads of problems can arise in the assembly process if the parts are not separate. Certain parts may include RF components, essential components, lower-level analog, and whatnot.
  • Microwave and RF PCB assemblies also require impedance matching. Since such PCBs have mostly higher frequency ranges, the tolerance rate to impedance matching is relatively low or tight. Impedance matching can minimize the “skin effect loss.” Skin effect loss means turning signal energy into heat When a funnel Captures some of those electrons that flow outside the conductor on a PCB. Thus, keeping a proper impedance matching is a must in this case.
  • Another issue regarding the PCB design of RF and microwave boards is the return loss. Signal reflection and ringing are the leading causes of return loss. One should note here that ground planes present underneath the signal should not have any discontinuities or otherwise, there will be a problem of reflection and ringing.
  • Prevention of crosstalk is another factor that one should keep in mind before designing Radio Frequency printed circuit boards and microwave PCB. Crosstalk means the process through which there is an unintentional or unwanted energy transfer between adjacent conductors. It can lead to coupled signals and happens due to shunt capacitance and mutual inductance.

Determining the substrate materials in RF/Microwave PCB Assembly

Choosing substrate material in the design of RF PCB and Microwave PCB is necessary. It is because optimum substrate material is required to have reliable and well-performing PCB. Thus, well-chosen substrate materials play an essential role in the designing process of boards. There are certain things you should focus on while considering substrate materials, which are as follows:

  • You should make sure that the RF and Microwave PCB should have substrate materials having high relative permittivity. It is because of high relative permittivity All the demands of waste and space regarding the PCB. Also, the ratio between the dielectric constant and vacuum permittivity is known to be the Relative Permittivity.
  • You should also consider the environment while considering substrate materials. One should make sure that there is temperature stability. And there should be the highest and lowest temperature limit. Once you choose substrate materials that can absorb less humidity, there wouldn’t be any compromise in a circuit board’s performance in a high humidity environment.
  • Substrate materials should be thick so that a circuit cannot bow, distort, Manufacturer setbacks, increased cost, or dielectric breakdown. However, Substrate materials having thick per area units can cost more than thin ones.
  • The relative Permittivity and the loss tangent have a function that is a dielectric loss. Substrate materials, shorter lines can offset dielectric loss per unit length, thus reducing conductor loss. It is crucial during high-frequency situations.

Conclusion
Overall, we can say that Microwave and RF PCB Are the best types of PCB that you can assemble. Such PCBs can capture higher frequencies. Higher frequencies capturing quality means better functioning. However, having a higher frequency also means various problems in the designing process. Higher frequency signals tend to be suspective to noise and need well-designing methods so that no catastrophe can take place. Some guidelines for designing such PCB needs to be adopted, as you can see in this blog. And, one should use properly efficient and reliable substrate materials in Microwave and RF PCB assemblies.

Technotronix offers professional PCB Assembly services with 40 years of expertise. Our accurate PCB assembly process meets the quality standards, including ISO-9001:2015, RoHS, and more. You can rely on our PCB design tools that, in turn, lead to that perfect PCB Assembly. Our superior engineering capabilities mean that each board matches your exact requirements and technical specifications.

If you have any questions or any requirements related to PCB assembly service, please feel free to contact us via email at [email protected] or call at 714/630-9200.

Top Manufacturing Factors That Affect the Cost of Custom PCB Assembly

By | Date posted: | Last updated: April 6, 2021
Custom PCB Assembly

Every part of a PCB is specific and will be incomplete if all parts are not available. Each PCB that you can find is unique on its own. And the cost for such a custom PCB assembly services will vary depending on several factors.

The problem takes place when you incur additional costs than what you have expected. You might want to know a way through which you can get a good idea of what your custom PCB Assembly costs would remain. Let’s discover which factors affect the Custom PCB Assembly and how?

Manufacturing details – what affects the custom PCB Assembly costs?

Often the question is, “What manufacturing details affect the cost of Printed Circuit Board assemblies?”. And the answer lies below:

Unavailability of PCB Design

If your PCB design is not ready for assembly, then arises additional costs issues. Several factors for DFM or design for manufacturability changes and even analysis is essential when there is designing unavailability. All such matters may lead to a rise in its manufacturing costs.

Lack of documentation

What’s the main thing for custom PCB Assembly? It’s the data. Thus, if there is a lack of documentation or incomplete information, the manufacturer would incur several problems. Then, they will have to analyze everything again, which can take more time. More time will slow down the assembly process, which somehow affects its costs.

Once you are sure that design and documentation are proper, let’s move on to the other factors affecting the custom PCB Assemblies:

PCB Layers

Layers of the PCB are a crucial factor affecting the PCB cost. Sometimes, using fewer layers on your board could reduce manufacturing costs. However, it is also to be noted that using more layers would increase its functionality.

HDI Technology

HDI or High-density interconnect design matters a lot in the cost for custom PCB assembly services. Even though it makes a PCB better, try to avoid using it as long as the circuitry doesn’t need it. It is because HDI technology may increase your costs.

Controlled Impedance routing

There are specific layer stack-up necessities for a PCB that necessitates controlled impedance routing. If you don’t do it in advance, you would have to alter the PCB again, which will increase the costs once again.

Through Hole or SMT Assembly

You would notice that Surface Mount Technology is automated in most manufacturing facilities, reducing labor requirements. Thus, it helps in lowering your Custom PCB Assembly cost.

On the other hand, Through Hole technology is a traditional method and requires more labor, which increases manufacturing costs. Thus, using this method fewer might be a better idea.

Printed circuit board assemblies finishes

The finishing of the custom Printed circuit board assemblies might have a hand in affecting the manufacturing costs. Thus, you need to check how your PCB will be finished. For example- in terms of soldering, the lead-free process will be costlier and even affect other components.

Custom PCB Assembly requirements that increase its costs

The factors mentioned above, but there are several requirements for PCB assembly that increase its costs.

There will be several cases regarding the custom PCB Assembly. The PCB might meet your manufacturer’s standard board assembly flow or maybe not. It does, then everything is fine.

However, if not, then you would have to make alterations to the materials of your PCB. Making alterations will result in increased costs. Changes are essential since not all components can go through the assembly process.

There might be another issue if some of your PCB’s mechanical hardware may not be ready for assembly. It will increase your cost even if the contract manufacturers solve the problem.

Another requirement for Custom PCB assemblies that increase their cost is testability. Testing is crucial, and a manufacturer can help in finding an excellent way to do it.

What is the role of your PCB Contract manufacturing partner?

Apart from testing, there are several other factors through which a manufacturer can help you. As you know already, you need a properly functioning PCB to meet your ambitions, and a PCB manufacturer can help you with that.

They will review and analyze the PCB from an engineer’s perspective. They will check and even clean your bill of materials (BOM). What’s more, is that they will also help in the PCB testing.

Thus, whatever your requirements may be, a PCB manufacturer can help you with it. They can even tell you what components suitable and which ones are not.

As you can see above, several factors affect the cost of a Custom PCB assembly services. Even some of its requirements (that are unavoidable) may increase the costs of PCB assembly. Thus, you need to check all such factors and reduce all the expenses as per your requirements.

Technotronix offers professional Custom PCB Assembly with 40 years of expertise. Our accurate PCB assembly process meets the quality standards, including ISO 9001:2015, RoHS, and more. Our superior engineering capabilities mean that each board matches your exact requirements and technical specifications. In case if you have any questions, please feel free to contact us via email at [email protected]

Request a quote for Custom PCB Assembly!

Why and when you need to outsource electromechanical assemblies?

By | Date posted: | Last updated: February 16, 2023
electromechanical-assemblies

Electromechanical assemblies are increasingly becoming an integral part of major electronic products today. These are fairly complex assemblies comprising of circuit cards, custom cables and other electro-mechanical elements. For a product manufacturer, therefore, both capabilities as well as resources could undergo a severe strain in producing them. Manufacturers are therefore typically faced with a “build or buy” choice. The choices before you are clearly to either expend resources and competency mastering electromechanical assemblies or outsource it to people who have the necessary know-how and access to industry best practices to offer cutting-edge products.

One look at the numbers and it is clear that the scales tip in favor of outsourcing. The global market for electronic contract manufacturing is estimated to reach US$ 653.8 Billion by 2027 as per estimates by Strategy. Not without reason. There are many advantages of contract manufacturing PCB assembly. But here we are discussing outsourcing electromechanical assemblies, so its advantages are as follows:

Specialized Equipment

The first major advantage that contract manufacturers have is that of having state-of-the-art equipment. Whether it is wire cutting and crimping machine or a CNC mill, they invest in specialized equipment to build the assemblies. What they also have is rigorous testing protocols that ensure percentage of error is miniscule. For an OEM to invest in this kind of machinery and floor space for producing one component may not work out to be cost-effective at all.

It works far better for them to focus on their core competencies, and put that floor space to better use in creating the product that they produce, to increase their profitability.

Specialized Manpower

Once again, this is an area where contract manufacturers have an advantage. They recruit and train skilled manpower that specializes in Electronics Manufacturing Assembly Services. This kind of investment in manpower may not be worthwhile for an OEM.

Quality Processes

It is very important to having the quality checks in place when it comes to electro-mechanical assembly. This enables contract manufacturers to create assembly after assembly with the same level of precision. This ensures the OEM will receive products that are fully tested and it will ensure the efficacy of their final product. Typically, the kind of industry-best practices that a contract manufacturer has access to, is quite hard to replicate. With their existing relationships with suppliers, they also have the advantage of sourcing quality parts at the most cost-effective rates.

Additionally, with process certifications and training standards you can rest assured that what you will get is a high degree of reliability.

OEMs agree that it isn’t all that prudent to invest in people, expertise and equipment when you can get a good price as well as great turnaround times from a contract manufacturer. What it also saves them from is shouldering the additional in-house work.

The other reason why doing it in-house does not make sense is that contract manufacturers find it hard to scale up quickly. So, if the demand is for higher production volumes, it may be worth it, but, on the other hand, if the volume requirement is low, the investment in technology and manpower can be extremely hard to justify. A contract manufacturer however is fully equipped to handle full production runs as well as small quantities so contacting a contract manufacturer is a smart choice in both the cases.

Clearly then, outsourcing helps save both money and time that can be put to better use and expand your business portfolio further.

To sum up, what you get by outsourcing electro-mechanical assemblies are:

  • A reliable product
  • Cost-effective prices
  • Quick turnaround time

All of this goes into the efficacy of your final product and gives you a tangible advantage of quick time-to–market. In a hugely competitive marketplace, the time spent in acquiring talent and infrastructure can put you considerably behind. With the contract manufacturer having the pre-existing competency for your requirements, quick time-to-market can be possible.

With the negative connotations around the term “outsourcing” no longer there, OEMs see it is as a necessary option. All you need to do is to choose your electronics contract manufacturer with care. You need to partner with the one who is committed to quality standards as well as quick turnaround times. Having identified such a contract manufacturer, what you have is not just a vendor of a sub assembly but your success partner.

Technotronix offers Electromechanical assembly services with 40 years of expertise. we take an extra step to reach out to your exact PCB requirements, high quality standards and strong customer support service to provide quick turnarounds and on-time delivery to our customers. In case if you have any questions, please feel free to contact us via email at [email protected]!

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