Why choose Automated X-Ray Inspection (AXI) Technology in PCB Assembly?

By | Date posted: | Last updated: April 8, 2022
AXI Technology In PCB

Simply put, Automated X-ray inspection or AXI technology as it is popularly referred to, uses X-rays to inspect the features of target objects. As an application, it finds place in a whole lot of industries today including but not limited to aerospace, medical, PCB Assembly and more.

X-rays go a long way in testing PCB quality as traditional inspection devices have their own limitations especially when miniaturization is on the increase. Also there are added issues of solder joints being hidden in some cases. X-rays however can penetrate and inspect quality of hidden solder joints as well. Therefore, while Automated Optical Inspection is only applicable for defects that are relatively easy to spot, such as open circuits or solder bridges, Automated X-ray inspection is required where inspection isn’t possible basis light alone.

The advantage with X-rays comes on account of the fact that materials absorb X-rays proportional to their atomic weight and depending on their density and thickness. Heavier elements thus absorb more X-rays as compared to lighter ones. Hidden defects, therefore, such as those to do with missing electrical components, shorts etc are far easy to catch.

An ideal X-ray system however must have clear images so that information with respect to defect analysis is clear and actionable. It is ideal, therefore, that the X-ray inspection system has adequate magnification as well as oblique angle inspection function. The latter ensures that solder balls aren’t just inspected from above.

X-ray inspection devices typically come in two forms- two- dimensional and three-dimensional systems. Both these can be operated off line and therefore make the inspection process easy. Some devices however can be used online. The choice of offline versus online devices typically depends on the amount of inspection required. In cases where there are large quantities to inspect and the level of inspection is complex, online devices are generally used. While a two-dimensional system can display 2D images of components from both sides, a three-dimensional system can generate images of cross sections. 3D systems can also combine images of a cross section in a method known as laminography.

The kind of resolution required also necessitates the need to choose the right X-ray tube, which is typically available in two categories- open and closed. Also the amount of magnification required determines the distance between the sample and X-ray tube. The X-ray voltage is yet another determinant of its penetration capacity. With a large voltage, objects with high density and thickness can be inspected easily. With single sided boards, however it is enough to go with low voltage. Similarly multi-layered boards call for high voltage.

The early inspection devices came with an image intensifier linked to a CCD Camera, the image intensifier, however, came with the following constraints:

  • Limited range- The limited range in turn implies that the area may need to be inspected with more than one technique. This in turn increases the time taken to satisfactorily carry out the inspection.
  • Limited field of view- At a given point in time a three to five inch diameter areas can be inspected.
  • Image blooming- There is a chance of the image bleeding at the edges as the ionizing radiation passing by the edge of the casting is not attenuated
  • Increased Noise levels- The image intensifier produces a noisy image. A clean, noise free image necessitates a digital processing of the image, which in turn is time consuming and does not let the process remain real time.

The above constraints however can be mitigated with the use of a direct digital imaging device. It not only offers a larger inspection area but also an improvement in resolution.

WITH X-RAY INSPECTION, WE CAN DO THE FOLLOWING:

  • Perform a non-destructive inspection
  • Locate short circuits
  • Detect voids in solder joints
  • Determine displacements of components
  • Examine semiconductors
  • Check switches, relays , plug and cable connections

 

The advantages of Automated X-ray inspection technology are as below:

  • Reliable and consistent results
  • Reduced time for inspection
  • Reduction in labour cost.
  • Effective process control as defects can be found in the early stage of the PCB assembly process and that it stops defects from flooding among the remaining PCB assembly.

 

Overall, therefore, X-Ray inspection technology is certainly a boon for PCBA manufacturers as it helps them improve product quality significantly. With the need for sub-micron resolution and extremely high definition images at high speed, the need for and the complexity of X-ray inspection technology will only grow. The way forward will be to be able to reduce the number of expensive operators as also remove the probability of human errors, if any, in the inspection process. This can be achieved by developing some inspection algorithms to be able to tackle these complexities.

At Technotronix, we are fully equipped to handle your PCB manufacturing requirements. With over 4 decades of experience in PCB manufacturing as well as PCB assembly with differing levels of complexities, we follow industry best practices to ensure we deliver cutting-edge products. Our team of experts and state-of-the-art equipment ensures that all our PCBs meet the industry standards of quality and testing. It is our vast portfolio of satisfied clients that stand as the biggest testimony to our success. In case if you have any questions, please feel free to contact us via email at [email protected]

Why Small Batch PCB Assembly should become your preferred method for all kinds of industrial projects?

By | Date posted: | Last updated: April 8, 2021
Small Batch PCB

With Printed Circuit Boards becoming an integral part of more and more devices, PCB prototyping is at an all time high. With companies continuously innovating, the need of the hour is small batch PCB Assembly which can offer high turnaround times without the manufacturer being stuck with high inventory that he is unable to make use of.

Advantages of small batch PCB assembly that are of immense value to a manufacturer:

Cost advantage

Although traditionally economies of scale are known to accrue with high volume of production, in an ever-changing technological scenario low volume PCB production comes with significant cost advantages. For one, you will not land up getting more boards produced than you require. Also, with changing technology the boards won’t be rendered redundant.

At the prototype stage, you are often improvising on the product, both in terms of design and functionality. Low batch production means that you aren’t stuck with faulty products. Also, since you are able to outsource PCB small batch. PCB Assembly, what it means in terms of your own business is lower overhead costs. You can also save on precious time that can be utilized in other productive areas of business. With lower batches you also tend to save on storage costs that can accrue in case you are stuck with a heavy inventory load, which is also dead inventory if the prototypes are faulty. Small batch PCB Assembly can therefore offer a low-cost testing method. A Small batch PCB Assembly can therefore offer a low-cost testing method. Check out Top Manufacturing Factors that Affect the Cost of Custom PCB Assembly.

Turnaround time

Low volumes also come with quick turnaround times. You can therefore assess if there are any design changes to e made, quickly. This, in turn leads to shorter time to market, which in today’s world can be a source of significant competitive advantage.

Agility

If there is one attribute that stands between business success and failure, it is agility of businesses to respond to changes. Small batch PCB Assembly inherently offers this advantage to businesses as businesses aren’t stuck with high volume of production as well as have the advantage of quick turnaround times. With improved ability to see whether there are any flaws in the product, whether the design needs any changes, businesses can be extremely agile in dovetailing the product to suit customer needs. Needless to say that the chances of success are increased manifold.

Quality Final Product

With quick turnaround time of PCB prototypes and the ability to detect flaws early, you have the advantage of improving the products and therefore to go to the market with quality products. This goes a long way in improved credibility as the product is successful in the market place and brings repute to the manufacturer.

Feasible for startups and hobbyists as well

Business these days is no longer the realm of large business houses alone. With small batch PCB assembly and the low costs associated with testing out ideas, business has become a level playing field. It is easy for small businesses as well as hobbyists to test their ideas with ease without having to invest large sums of money. For startups wanting to pitch to investors, it is also easy to have a proof of concept beyond just a business plan on paper.

To summarize, PCB small batch comes with multiple advantages, beginning from saving overhead costs by outsourcing your work. Small order sizes automatically lead to improved turnaround times. Also, it is an easy and low-cost way of testing product design ideas without incurring a whole lot of cost.

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]

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The Choice of PCB Assembly plays a major role in speeding up or slowing down supply chain

By | Date posted: | Last updated: September 7, 2024
PCB For Supply Chain Speed

In supply chain management, a single weak link can significantly impact your business. For those in the electronics industry, printed circuit board assembly (PCBA) often becomes that critical link.

Selecting the right PCBA supplier is crucial. It’s essential to choose a supplier who not only ensures high-quality standards but also leverages their experience to enhance supply chain effectiveness.

One key benefit of choosing the right PCBA supplier is their ability to audit not just PCB layouts but also prototypes. This means they can align engineering schematics with speed considerations from the start, helping you bring products to market faster.

To ensure that your supply chain operates efficiently, consider these strategies. By integrating printed circuit board manufacturing into your supply chain, you can address potential bottlenecks and speed up your production process.

#1 Have proper communication channels

When you are on a tight deadline, there is little scope for a communication breakdown. Ensure therefore that communication with the PCBA is clear and responses are not delayed. It is best to avoid assumptions as far as possible and put everything in clearly understandable terms, well in advance as far as possible.

In fact good partnering practices with your PCB supplier include:

  • Routine conference calls between your team and that of the PCB supplier
  • Quarterly Reviews that are designed to review the performance metrics and any business updates. Ideally this can be a two way process with updates being shared from both sides related to any business growth, new products and more. Essentially any information that impacts the production process as well as the business relationship needs to be shared.
  • Supplier score cards with objective and subjective metrics is yet another process that should be maintained. Things such as on-time delivery, defect rates as well as communication issues and more should be flagged off from time to time so that everyone is aware of issues, if any.
  • You also need to ensure that the supplier has a quality improvement program in place with periodic reviews.

The above best practices will ensure that the process is kept under check and also that the equation with the PCBA is that of partnership and not just of a vendor.

#2 Ensure that your documentation is complete

Ensure that you have worked through your documentation well in advance and that the documentation includes the following:

  • Bill of Materials – Do remember to go by the format that the supplier prefers
  • Gerber Files
  • XY data file
  • Stencil Files
  • Special assembly instructions

If there are any sub-assemblies that need to be manufactured in advance, it is also imperative that you have a bill of materials for each sub assembly and estimate the lead time for the parts. It is also important to verify their compatibility with the finished product

Try and avoid any last minute changes to ensure that everything is in order well in advance.

#3 Identify parts which have long lead-time

Ever so often electronic components have long lead times, often running into months. Identifying these components early can help the PCBA look for either alternate parts or source suppliers who have shorter lead times. In turn this can help cut lead times significantly as also impact costs.

#4 Forecasting demand

Keeping the PCBA posted on the demand forecasts instead of waiting to inform them of out of stock products at the last minute can also go a long way in keeping cost in check. It is commonly known that express shipping can come at a far higher cost and can derail the overall costing. Keeping the supplier posted on demand forecasts, on the other hand can offer the lead time to procure supplies at efficient rates.

#5 End to end partnership

Look for a PCBA who can provide end-to-end solutions and can assist you right from the conceptualization to the production phase. This will streamline the entire process and will cut down time.

The above steps when followed can ensure that the PCB Assembly process and the PCB Assembly provider does not become the weak link in your supply chain and is instead recognized as a critical part of the entire operation.

Turnkey PCB Assembly – A Comprehensive approach to get instant PCB quote and production

By | Date posted: | Last updated: September 4, 2024
PCB Assembly

The traditional approach to PCB assembly is riddled with many problems, foremost among them being the fact that it is high on cost besides being a long-drawn process. Also, it typically supports large orders and isn’t suited for prototypes. Turnkey PCB Assembly therefore comes in handy as it serves as an antidote to all these issues faced with traditional PCB Assembly.

Essentially Turnkey PCB Assembly leverages cloud based software and makes the process of developing printed circuit boards hassle free. All you need to do is to upload a design. With Turnkey Assembly Services then the vendor deals with the entire assembly process including material procurement, PCB fabrication and assembly, testing, packaging and fulfillment.

Also checkout : PCB Assembly Service Quotes

Some of the advantages of Turnkey PCB Assembly include:

Prototyping

While traditionally creating a prototype is a lengthy process that involves dealing with multiple vendors, sometimes contending with out-of-stock-components and overall large lead times, Turnkey PCB Assembly allows for quick prototyping which in turn significantly reduces the time-to market. Needless to mention that it is a major source of competitive advantage.

Works for small orders

Traditional PCB Assemblies cater to large order batches and therefore aren’t conducive to prototypes as well as small orders. Turnkey PCB Assembly on the other hand, by virtue of being able to combine several small orders into a large run, can cater to any order quantity with ease. Irrespective of your order size you can therefore get exemplary service which otherwise can be a prerogative of large quantity orders alone.

Shorter Development Cycle

Turnkey assembly has a much shorter development cycle than traditional PCB fabrication, which in turn means that the PCB’s cycle from assembly line to market is much shorter. This is largely on account of the fact that time isn’t lost switching from phase to phase. Time saving is also on account of the fact that you deal with one vendor for your end-to-end requirement. With a shorter development cycle you tend to gain significant advantages when it comes to proactively responding to changing customer preferences.

No need to deal with multiple vendors

Turnkey PCB Assembly takes away the need to deal with multiple vendors, thereby reducing chances of miscommunication. With multiple vendors you often also face the issue of any delay causing a ripple effect. Also in case you need to make any changes, you need to find the right person who can execute it. It helps to have a single point of contact who can answer questions and implement any changes. Not to mention the fact that with one vendor assembling your final product, peace of mind is a given!

End-to-end services

Turnkey PCB Assembly typically offers end-to end services comprising of product assembly, inventory and shipping. This offers a number of advantages. Besides the logistical ease of a having one point contact, it also saves time as there are no cascading delays.

Perfect for small businesses

On account of the fact that Turnkey PCB Assembly can offer limited quantities as well as quick turnaround time, it works well particularly for startups and small businesses.  With professional prototypes delivered in short time spans, it becomes far easier to pitch the idea to investors as startups have an effective proof of concept to showcase.

Turnkey PCB Assembly also works well for Kickstarter creators who aren’t sure of the volumes they would require and hence cannot commit to large numbers at one go. The flexibility in quantity offered by turnkey assembly services also work well for hobbyists who want to experiment with ideas. Besides being a boon to small organizations, they can also work well for larger set ups that are nimble.

Identifies Problems Early

A major advantage of Turnkey PCB Assembly is also that it can identify any manufacturing problems early on. The manufacturer can identify any errors in design that can be corrected early thus saving the manufacturer from paying a heavy cost on account of design issues. In turn, it also helps establish better design practices in the long run.

Consistency

With Turnkey PCB assembly, consistency of results is a given thereby ensuring stringent quality standards. The importance of quality cannot be overemphasized in today’s competitive environment where a single inconsistency can lead to loss of reputation especially with social media on an overdrive.

From Concept to Delivery

With PCB fabrication, procurement, assembly, testing, packaging etc being taken care by the manufacturer, it eliminates a whole lot of stress while the vendor takes care of everything. You can therefore focus on perfecting your design and bring high quality products to life, far faster. Essentially then, with turnkey services there is a significant freeing of time for your team, which can in turn be used in other areas that need the manufacturer’s attention.

At Technotronix, we have over 4 decades of experience in offering high-quality custom boards. Our state-of-the-art machinery and experienced manpower can offer you products that are way ahead of the curve. Additionally, we have a huge vendor network when it comes to sourcing components. What that means for you, is that we offer you high quality products with a quick turnaround time and at optimal costs. A range of clients across industries have gained a competitive edge with our turn key PCB Assembly, California with our consistent delivery of high-quality, on-time, price-competitive products. To know more, please explore our PCB Turnkey Solution!