Top Techniques to reduce the cost of cable assembly manufacturing!

By | Date posted: | Last updated: June 7, 2024
Cable Assembly Manufacturing

Custom cable assemblies, an important aspect of industrial projects, are also known to add to a sizeable portion to the overall costs. Often times cable assemblies need custom designs that can be complex and cost saving therefore involves a strategic identification of opportunities.

Here are some aspects to be mindful of, to be able to optimize costs.

First things first, even before we get to the cost, it is imperative that a detailed bill of materials (BOM) be available. It is a careful analysis of this document that can lead to cost saving suggestions. Additionally, a full specifications list must be available. Once again a thorough evaluation of the specifications can suggest areas of cost optimization without impacting the quality.

What are the techniques used to reduce the cable assembly manufacturing cost?

#1. Make sure that the design isn’t over-engineered & components aren’t over specified

It is imperative to choose the right design that lends itself to ease of manufacturability as also to cost optimization.

Making the choice of the right raw materials is extremely important basis the design. Importantly, the choice should be made because of the right reasons. Sometimes the choice is made simply because of familiarity with certain components or the fact that the components are top-of-line. The fact remains that components need to be chosen based on the bespoke requirements of the project. If, for example, the cable needs to be used in an environment where the temperature is high, due attention must be paid to how high the temperatures are likely to be. Over specifying the components can significantly add to the costs without giving you any tangible benefits.

Also explore more information about Circuit Board Component Placement.

#2. Choose the right connectors

Speaking of components, due care must be taken to choose the right connectors. For this, it is important to understand the transmission that the assembly will handle. Different types of connections require different methods, which in turn have cost implications. You need to make sure that the chosen technique works well for product quality while optimizing costs.

#3. Make the right choice of cables

Assessing your transmission needs is key. If you are looking for regular transmission you can opt for unshielded cables. However, if you specifically need to cancel electromagnetic noise you should go for shielded cables. Using shielded cables where unshielded ones can make the cut, can lead to an unnecessary increase in costs.

#4. Choose the right conductor size

It is also important to choose the right conductor size. Typically, the smaller the conductor size, the lower the costs. Of course, the size has to be chosen in a manner that doesn’t impact quality.

A thorough evaluation of the design could offer you areas of change that can significantly reduce costs without compromising on performance.

#5. Optimize supply chain management

With a professional PCB supplier, You will be able to save costs on the supply chain. For instance, the supplier could be ordering components in bulk and therefore driving down prices on account of economies of scale. Similarly, your supplier could produce a few months’ worth of cables and send them to you as they are required. Building trust with the supplier plays a strong role here.

You also need to ensure that the supplier is great at customer service and acts like a partner in the project.

#6. Choose the right partner

When you are outsourcing complex custom cable assemblies, it goes without saying that the right partner can make or break the project. The ideal partner will help you bring down the cost through:

  • Due advice on design & component selection. With access to industry best practices the partner will ensure prudent selection
  • Creative sourcing of parts that will keep costs under check.
  • Due quality control measures which ensure, that there aren’t costly errors to pay for at a later date.
  • Robust testing goes a long way in ensuring that there aren’t corrections to be made later that result in huge costs on account of wasted time, manpower & material.
  • Robust customer service including speedy resolution of issues, if any.

To sum up

While you need to optimize costs you cannot do it at the expense of non-existent quality control mechanisms. In taking the cost quotations from the partner, ensure also that you can vouch for their quality control process. It is imperative that the partner has an unstinting focus on delivering high quality at the most cost effective price points. Their long-standing supplier relationships can ensure that they are able to procure parts at optimal prices. Additionally, with their expertise & access to industry best practices, they can make sure that you do not need to re-invent the wheel. Their robust customer support team could also help in making sure that each project is delivered seamlessly.

Technotronix is a professional PCB manufacturer with 4 decades of experience and ISO 9001:2015 certified who is equipped with the necessary industry best practices. Feel free to ask if you have any questions regarding cable harness assembly services. Your satisfaction is our primary goal!

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Top power supply PCB assembly guidelines!

By | Date posted: | Last updated: December 5, 2022
Power Supply PCB Assembly Guidelines

All PCB boards need electrical power; however the need isn’t just for more power but also clean power. That is something that is made possible by a successful PCB board design. With the right PCB design, clean, uninterrupted power can be provided to the circuitry. It is also important to remember that electrical power will generate heat & the heat, in turn, will impact the circuit board. A number of aspects therefore need to be kept in mind.

Before we look at some of the considerations that will lead to a cleaner power supply, it will be worthwhile to look at the kind of power supply available.

Broadly, power supplies are broken up into two main groups:

  • Linear power supplies are typically used in systems where the power requirements are lower. 
  • SMPS or Switch-mode power supplies are more complex as also more efficient. The thing to remember is that their switching noise can lead to EMI. SMPs, in turn, may be isolated or non-isolated. Non-isolated SMPs are further of the following types:
    • Buck – It steps down the voltage while the current is stepped up
    • Boost – It steps up the voltage while stepping down the current
    • Buck-Boost – It has elements of both & can step up or step down the voltage.

It is important to remember that since you will deal with high levels of current, the trace widths need to be adequate. Additionally, in order to control the noise, it is important to ensure that the component placement is optimized as the routing is short. Also the design needs to ensure effective heat dissipation. Let us look at some of the guidelines to be followed in detail:

PCB Power Supply Guidelines to follow:

  • When you are dealing with a multi-layered board, it is important to have the ground or power plane between the outer layer with the power supply components & the inner layer with sensitive signals. The ground plane offers electromagnetic shielding. In case it is not possible to devote a layer, a ground polygon is ideal. If you do go in for a ground plane, it is essential that the PCB power supply design is separated from the common ground. Also the connection between the two grounds should be limited to one point on the board. In the absence of this, you run the risk of ground loops.
  • It is imperative to keep the power supply parts close together so that the trace lengths are minimized. This will help to reduce any resistive losses as well as electromagnetic noise emissions. Where possible the use of polygon pours is recommended.
  • In terms of component placement, it is also important to separate heat-generating components from heat-sensitive components. Also using copper will ensure that heat is distributed from the hotspots and that thermal issues aren’t exacerbated. If you are dealing with a buck converter the input capacitor should be kept next to the IC. As for the output capacitor, it should be placed immediately after the conductor.
  • Speaking of heat dissipation, it is important to include proper cooling methods such as heat sinks, fans, thermostatic coolers & more. Heat sinks are, however, best used with a linear regulator.
  • As for the routing, it needs to have short, direct traces. As far as possible blind and buried vias need to be avoided as they add to the inductance.

To Sum Up

The above best practices will ensure that your PCB power supply is optimized. However, a key area remains, which is having the boards manufactured & assembled to these exact details. Choosing the right electronic contract manufacturer who can manufacture & assemble your boards as per these best practices is therefore essential. Among other things since the PCB requires tight placement, you need an experienced assembler who can take care of all the requirements. Typically, the manufacturer & the assembler need to be able to work with you at the design stage itself so that there are no manufacturability issues at a later date. An experienced manufacturer & assembler is also equipped with all the industry best practices that make sure that you do not need to reinvent the wheel or waste precious time, especially since quick time-to-market is a key competitive advantage in today’s times.

At Technotronix, we are fully equipped to handle your PCB manufacturing requirements. We follow industry best practices to ensure we deliver cutting-edge products. Our team of experts and state-of-the-art manufacturing facility ensures that all our PCBs meet the industry standards of quality and testing.

If you have any questions or any requirements related to PCB assembly, please feel free to contact us via email at sales@technotronix.us or call 714/630-9200.

How to create precise PCB assembly drawing quickly and efficiently?

By | Date posted: | Last updated: November 17, 2022
PCB Assembly Drawing

Precise PCB assembly drawings are the key to success for a PCB project. With detailed drawings, it is that much easier to get the exact output that you have envisaged. In creating these drawings, however, need you to keep a number of important aspects in mind:

PCB Assembly Drawing

1. Bill of Materials

A very important component of your design is the Bill of Materials. Among other things, it goes a long way in making available the component shapes and reference designators on the board that makes the assembly process seamless. You will also need to include mechanical parts that may need to be attached to mounting hardware. Besides the drawing needs to identify the exact components required as well as the materials. Manufacturing labels need to be identified as also referenced in the notes.

Some of the best practices to follow when a metal element needs to be used, for example, include:

  • Specify the metal to be used.
  • Specify the finish that the metal needs to have.
  • Specify whether it needs to be painted or powder coated.

It is also prudent to include additional views. The double-sided boards, for example, will benefit from providing a view of the front and back of the board. Also, where mechanical parts are being added, expanded views will help provide clarity.

The more details you provide, the more the board will live up to your specifications. As they say, “God is in the details!”

2. Specify the dimensions

It is imperative that all dimensions are specified in detail. To do that, it is best to use a CAD program. A board design software such as Altium or PADS works well.

In a wiring diagram, it is also important to demonstrate the connections for custom cable assembly as well as the type of termination that needs to be used.

The use of the right software makes sure there is precision & the final assembly lives up to your specifications.

3. Ensure you attach relevant files

When it comes to PCB assembly, it is essential for the contract manufacturer to have the following files:

  • Gerber Files
  • Drill Files
  • Silk Screen Files
  • Placement & Drawings Package

Ensuring that the assembler has the exact details of where the holes need to be drilled and where the components need to be placed will ensure success of assembly.

4. Detail the testing requirements

It is important also to think through the testing at the outset and indicate the same to the PCB assembly partner. That way there are no rude surprises at the end.

In fact, it is extremely important to specify to the contract manufacturer whether you will be requiring programing. In which case, the programming files will need to be included and the exact programming will need to be specified.

5. Any special PCB assembly drawing requirements

You also need to think through any special requirements of your project and add a quick note in the drawings. Some examples of the special requirements to be mindful of, include:

  • Whether you require lead free assembly.
  • Any special requirements when it comes to packaging of the product.
  • Export documents that are required, in case the product is being exported.
  • Any other Assembly notes that could include industry standards and specifications, special feature locations & more.

To sum up

While a lot of these details go in to successful PCB assembly of the board, you may also find the process daunting. The good news is that there are PCB design systems available that use automation to create drawings. These tools go a long way in saving time and energy while ensure that the drawings are extremely robust. In short, these tools with their powerful automation help you create PCB drawings, both quickly & efficiently.

The choice of the right PCB contract manufacturer is also extremely crucial in making your PCB assembly process, a success. Armed with experience and industry best practices, they ensure that you do not have to reinvent the wheel. Any flaws in the design are pointed out by their engineers in the early stages saving you from costly errors that accrue from discovering these issues once the product is ready to be shipped, or worse still when it has already hit the market.

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

Request PCB assembly quote for your any type of requirements.

Why PCB assembly service quotes are essential for your PCB projects?

By | Date posted: | Last updated: April 19, 2023
PCB assembly service quotes

Once you have a PCB design in place, you need a competent manufacturer who can bring your design to life at a price point that works for your project. It is important therefore that you ask for a PCB quote before the fabrication can kick off.

To get an accurate quote, however, it is important that you provide the manufacturer with the relevant information. Let us look at what a PCB assembly service quote consists of.

PCB assembly service quotes

Essentially, a PCB quote offers an accurate estimate of the cost of fabricating a board as also the timelines involved. A quote can be made available for both PCB fabrication as well as PCB Assembly.

It is necessary that you give accurate information about the project for both the price as well as the timelines to be accurate.

A PCB assembly quote, for example, will come with vital details such as:

  • Type of material
  • Number of holes
  • Number of layers
  • Board dimensions
  • Trace width
  • Finishing of copper layer
  • Space between traces, and more.

Required documents for PCB assembly quote

The accuracy of the quote depends on the availability of the following documents:

1. Bare Board Print or Fabrication Drawing

It offers information related to aspects such as:

  • Board thickness
  • Number of holes
  • Dimensions, and more.

It is also important to include details of the component numbers in this document. Along with this you also need to make available the Gerber Files.

Pro tip- Ensure that design files are made available in a format such as ODB++.

2. Bill Of Material

Bill of material is yet another crucial document that among other things carries relevant information about the components. The more detailed it is, including aspects such as description of parts, part number, reference designator & more, the smoother the entire process.

3. Assembly Print

With an Assembly Print information about the location of parts can be conveyed. It also contains special markings if there are any.

4. Approved Vendor List

An approved vendor list along with part number of the manufacturer is ideal.

Information that is often missed when requesting for a PCB assembly quotes

The following are some of the information that is often missed:

1. Stack-up details

This comprises of details of number of layers, thickness of layers as well as of the stack-up.

2. Solder mask details

These details include the type of solder mask, its finishes and more.

3. Impedance details

With impedance details not being provided; their implications are felt on several aspects of the board.

4. Cut-out

The dimensions as well as the position of the cut-out are imperative in receiving an accurate PCB assembly quote.

5. Silkscreen

Where to apply silkscreen & its color are also essential details.

6. Surface finish

The type of surface finish has a strong bearing on its cost. It is therefore imperative that it be clearly mentioned.

Factors that affect PCB assembly cost

Some of the other factors that impact PCB assembly cost include:

1. Mounting Technology Used

The use of SMT (Surface Mount) or through-hole PCB assembly technology has a bearing on the cost. Also, Surface Mount technology is faster as it uses a lot of automation.

2. Lead Time

In case your lead times are short, it has a bearing on the cost of the PCB assembly. The two clearly are inversely proportional.

3. Shipping Costs

Large PCB quantities may come with additional shipping costs.

4. Number of Layers

It typically costs more to assemble multilayer PCBs (Printed Circuit Boards). This is because the number of production steps has increased significantly.

5. Surface Finish

The choice of surface finish as already indicated has a strong implication on the cost. Some of the surface finishes come with longer shelf life and at a higher cost.

To Sum Up

While a PCB assembly quote is important for you to plan the efficiency of your project, its accuracy depends on a whole lot of factors. It is important that the details must be correctly provided so that the PCB assembly quote can be exact.

Needless to mention, however, that the quote cannot be the sole reason you go with a certain contract manufacturer. It is imperative that you ascertain the experience and quality offered so that there are no costly errors to deal with at a later stage.

To avoid such errors, you can contact Technotronix at sales@technotronix.us to get innovative PCB assembly services. With an experienced team, Technotronix provides reliable PCB services including PCB fabrication, assembly, and PCB design. Get a quick PCB assembly service quote for any kind of requirements.