How can SMT (Surface Mount) Assembly Process help to reduce manufacturing cost?

By | Date posted: | Last updated: July 15, 2021
SMT Assembly Process

Surface Mount Technology is essentially a constituent assembly technology that works by attaching and linking components on the board surface through solder-reflow procedures. It offers a number of benefits including the fact that it lends itself to miniaturization as it allows components to be placed in a relatively small space. SMT also is a great enabler when it comes to automated PCB assembly.

Cost-Effective technique

One area where SMT scores significantly is on the aspect of cost saving. While there is an initial expenditure in terms of machinery cost, the positive side is that the machines go a long way in minimizing the manual procedures. This results in a dual benefit. The first that the long-term labor cost is reduced. Importantly, it goes a long way in improving production efficiency, which in turn, lowers cost. With surface mount assemblers using a software to digitally assemble the board prior to actual production, possible errors are minimized. It also has a positive impact in terms of minimizing delays that can prove to be costly.

Here is a detailed analysis of the entire SMT Assembly process that will enable you to understand the cost reduction possibilities at various stages.

The broad stages involved in the SMT assembly process include:

  • Solder Paste Printing
  • Solder Paste Inspection
  • Chip Mounting
  • Visual inspection
  • Reflow soldering
  • AOI
  • X-Ray Inspection
  • ICT
  • Functional testing
  • Depanelization

Solder Paste Printing

This process involves placing an accurate amount of solder paste onto the pad on which the components are to be soldered. For this it is not only important that the solder paste is applied well but also that it is stored correctly at low temperature and brought to room temperature prior to application. In addition, due attention needs to be paid to the scraping angle and speed.

Solder Paste Inspection

This step goes a long way in reducing costs as it helps detect SMT Soldering Defects early. What it enables you to do is to prevent costly defects in the later stages of manufacturing.

Chip Mounting

An essential component of the SMT assembly process, this is completed by way of chip mounters. While small components are placed by way of high-speed chip mounters, the larger components require multi-function chip mounters that run at a low speed.

Visual Inspection

The process of visual inspection once again ensures that any defects can be identified early. Some of the errors that can be identifies at this stage include any missing parts or lack of proper placement. Post the reflow soldering it will be very hard to deal with these defects. Once again, this stage of SMT assembly allows scope for keeping costs in check as if this stage isn’t carried out, you can expect that to rectify the errors later, the production cost will rise.

Reflow Soldering

This process involves melting the solder paste to be able to connect the components to the board. It is the temperature profile setting that determines the reflow soldering capability as also reducing the production costs. A professional assembler can go a long way in keeping the costs in check.

Automated Optical Inspection

At this stage the performance of solder joints is thoroughly inspected. Some of the errors that can be detected at this stage, include:

  • Tombstone
  • Edge On
  • Missing Components
  • Misplacement
  • Bridging
  • Empty solder, and more

Automated X-ray Inspection

Once again, X-ray inspection is a great way to ensure high efficiency of the product and to not having to contend with product defects once the product is sent out into the market.

ICT or Function Test

This test checks for opens and shorts and exposes any defects of components by measuring aspects such as:

  • Resistance
  • Capacitance
  • Inductance

Function tests also go on to test the functions of the assembled PCB to ensure that the final product is extremely reliable.

Over all, therefore, the SMT process has a number of in-built checks to avoid costly errors. These measures drive the final products to display high reliability and integrity. Little surprise then that Surface mount technology for PCB assembly is generally considered to be the lowest cost and minimum hassle process when it comes to new designs.

At Technotronix, we are highly cognizant of the above guide. We have over 40 years of experience in SMT PCB Assembly. With automated SMT Assembly process our boards ensure optimal performance in the most challenging applications. If you are looking for progressive SMT PCBs solutions, you are at the right place. To know more, please explore our PCB Assembly Services!

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Top innovative strategies for automotive PCB assembly

By | Date posted: | Last updated: February 15, 2023
Automotive PCB assembly

From a mechanic to the aerospace sector, the application of the print circuit board has grown for years. Currently developing, so is the need for material progress and ability. Before smartphones and internet madness, PCBs have been widely used – from toys to combat jets. There is a time when a pocket calculator is considered high technology. When people depend on technology, newer innovations continue to be introduced. Electronics Manufacturing Industry have become more assertive, compact, and moving. Accustomed people are connected. The progress that provides more excellent connectivity is also needed to be packaged into each PCB.

Top Automotive PCB Assembly Strategies

For automotive PCB assembly, it requires selecting appropriate materials and a specific design that fulfills the requirements proposed by applicable standards and the ability not to experience problems during production. Therefore, it is recommended to follow several basic strategies as mentioned below.

Component placement and orientation

Placement components and orientation play a fundamental role in determining the board manufacturing’s performance, reliability, and capabilities. When the wave solder is used, the component must be oriented to the direction parallel to the wave direction to prevent bridging soldering or open circuits.

Routing of the signal

Components that absorb more than 10mW or do more than 10mA must require appropriate thermal management and power management components. Power and Ground Planes must be placed on the internal layer. It is better if symmetrical and central elements prevent the bending board. Sensitive signals (such as hours) must be protected from noise sources by plane and controlled impedance. Connections between layers that do high currents must be made using two to four Vias per layer; The use of several Vias allows, in reality, to improve reliability, reduce resistive and inductive losses and increase thermal conductivity.

Sequence and Unique components

More fantastic components (usually most important) are placed first, followed by more minor parts. In addition, analog or mixed components must be placed in a particular PCB area, separating it from the digital member. Significant details are also important: high components (such as electrolyte capacitors) will not be placed next to shorter because this avoids a solder connection that is not severely connected. Applicable rules are maintaining a viewpoint above 45 degrees because this helps manual solder joints inspection.

Thermal Management

The first step consists of identifying components that disappear the most considerable amount of heat, look for the thermal resistance ratings reported in the datasheet. Heat is transferred from members to copper layers, and, as a result, ideal thermal management occurs when the entire board is at the same temperature. Trace thickness, number of layers, thermal path continuity, and the board’s surface are all factors that affect the climate of the operating components.

Thermal vias have the same job as the copper fields. Both are inclined to increase the conductive nature. Using several soil fields and power connected directly to heat sources through thermal Vias, the operating temperature can be reduced dramatically. If several components produce a high amount of heat, it is better to distribute it evenly on the board, thus avoiding hot spots. If, on the other hand, the heat generator is concentrated in several components, it is better to place it in the middle of the board so that that heat is dispersed uniformly in all directions.

Apply DRC rules

Check design regulations must identify problems or errors that cannot match general manufacturing requirements, high-speed electrical requirements, or other requirements for your particular application. It is strongly recommended to run DRC throughout the design process, not only in the end so that it identifies potential design problems early and fix them quickly.

Modern application in the automotive industry

Technology has fully grown into all parts of our lives – including our car. Demands for safety, comfort, and connectivity require a circuit board design to maintain speed – if it doesn’t remain one step ahead. Progress in the automotive industry means PCB applications must accommodate this complex system.

Industrial Truck & Shipping

From various surveys, we can state that as many as 38% of the commercial truck operating costs place humans in the driver’s seat. Price of each thing is increasing at a rapid pace. Thus, people are looking for great alternative with the same benefits. Similarly, the truck sectors are looking forward to such techniques in the field of technology and modern business.

Personal car

While the truck industry may see autonomous vehicles to save costs, the consumer market focuses on other purposes. At present, private cars offer extraordinary technology capabilities made possible by the print circuit board system. However, it is a potential benefit of safety that makes the appointment of car driving so interesting. This is not a problem if but when we will see the vehicle going alone.

Powertrain element

Automatic vehicles need advanced formulas to make them work. The machines seek for specific modifications in the monitoring feature with a view to rationalize the PCB design.

Comfort and Technology Features

It is straightforward to expect those automotive features such as smart locks and navigation systems need computers. The less clear – including many automatic sensors and braking systems – also spiced throughout modern cars.

Advanced Driver Help System

The fennel system is an electronic safety measure that provides sophisticated protection. The system protection system comes with modern amenities like the camera and light features, which improve the changes to avoid accidents.

The Era of the random vehicle advancement

Autonomous drones navigate highways and set goals – while managing to avoid plowing anything along the way. We will soon see driverless cars on road.

Conclusion
The automobile has grown into a collection of complex systems and software – even with humans in control. With ambitions to have a vehicle take over driving, too, the brain of this decision-making vehicle must have the highest quality. Now at the electric charging station in the future, it will charge your car’s cost like a smartphone, and you will then drive your car more “energy efficiently” and more environmentally friendly. Therefore, the EMS, PCB assembly providers are an integral part of the automotive industry.

TechnoTronix is an ISO 9001-2015 certified with having 4 decades of experience in providing PCB industrial solution. We have state-of-the-art equipment and an experienced team that can deliver quality PCB assembly and prototypes that do justice to the ever growing and dynamic demands of automotive industry.

The Top Reasons Why Medical Cable Assemblies Should be Selected Carefully

By | Date posted: | Last updated: June 15, 2021
medical-cable-assemblies

The medical industry is a very sensitive field and needs you to be very careful when dealing with it. A small mistake can even pay back hundredfold dangers than you can imagine. Failure in functioning or delaying work can cause a major risk of health injury in patients. To avoid such mistakes, every device and medical equipment needs to work properly.

Cable assembly plays an important role in the safety and security of medical applications. So, at the time of manufacturing, you need to carefully choose the Medical Cable Assembly for the best results in the healthcare appliances.

As you can notice, it is a crucial decision to choose. In the article, we discussed the important features you have to look at during the time of choosing medical cable and wire harness assembly.

Top Points you must consider during Medical Cable Assembly Selection:

As many aspects are dependent on your decision during the time of selection of cable assembly manufacturer, it seems a lot of pressure on your decision. Several factors you have to notice, some of these are mentioned below –

The durability of the Assembly:

Durability is a concern to consider. The stability of the medical equipment directly affects the potential of the service. Sometimes the device may be carelessly handled by the medical team or patient, but the equipment has to have such potential to withstand such resistance.

In some adverse environments also, the device needs to function appropriately to provide the treatment to the patient uninterruptedly. Any delayed function or malfunction may cost the life of patients.

It is not only durable, but long-lasting equipment is also economically effective as it has less chance of functional error, which means less repairing cost.

Signal continuity:

It means the capability of providing an uninterrupted, steady, accurate power supply of the Assembly. The importance of signal integrity in the medical field is precious because of the frequent use of emergency healthcare services. If there is an impaired condition on electricity, that may cause a serious issue in a crisis.

Reusability:

There are mainly two types of cables assemblies, one single-use and the other is disposable, reusable cable. Reusable cable is much preferable because it is cost-effective. The cable used in the disposable cable can tolerate the effect of sterilization which is done to make the hospital room germ-free. Sterilizer may be chemical or autoclave, but the cable must have the potential to withstand it.

An authentic reusable cable assembly is made up of such materials that can sustain the sterilization process. Reusable cable is purchased in many numbers; that’s why the price per cable becomes reduced.

Quality of the cable:

Good quality material is always preferable. A promising medical cable wire assembly components contain –

  • Conductor: It contains metal that transmits the electrical signal through the wire to the medical equipment.
  • Insulator: That contains some polymers compounds that resist the leakage of electricity from equipment to prevent short circuits.
  • Jacket: It helps the inner components to stay under the outer shell by covering it. It made the device easy to handle while the sterilization process became easy during the sterilization process.

Adaptability:

The cable must be the features to adopt any environmental situation. In need, the circumstances may change, but the cable has to do its wonder at any conditions.

The reason behind the careful selection of the medical cable assembly:

  • First, the medical field deals with human life, so anything concerned with health must be considered with keen observation. In the case of medical cable assembly also the rule must apply. There is no room for mistakes in this medical care, knowingly or unknowingly, as we have to make the equipment as error-free as possible.
  • Any error in the medical equipment can instantly cause deterioration of the patient’s health, which is against the oath of any health care professionals. And if anything happens to the patient, the finger of the allegation always tends to rise to the health care professionals.
  • Not only patients, default in equipment like a short circuit can cause mishaps to medical staff also. Anyone who handles technically defeated equipment is prone to an injury to any extent.
  • Good cable assembly leads to good health care services, which increases the brand value of your hospitality.
  • Any accident badly affects the reputation of your service because no one tries to compromise on their near and dear one’s health.
  • A frequent fault in medical equipment services also impacts the expense of the service because of the number of times it rips into more abundance in the requirements of the repair of the device.
  • Default service related to the hamper in the continuity in the services. If the device gets defective from time to time, the regular care gets interrupted.

Conclusion:
So, as you learn from the above discussion, the patient’s well-being admitted under the medical services is directly dependent on the functioning of the equipment used. The functioning of the device is conditional on the working potential of the medical cable and harness assembly.

Before using the medical cable assembly:

  • Examine it properly.
  • Investigate its working capability.
  • Testify that it doesn’t harm anyone by any means who handle it or on whom these are applied directly or indirectly.

TechnoTronix excels in providing PCB assembly solutions to medical industry. With over 4 decades of industry experience and rich knowledge, little surprise then that TechnoTronix has emerged as a preferred partner of choice across industries including the Medical PCB Assembly.

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The Complete Guide on Aerospace Electronics PCB Assembly & Design

By | Date posted: | Last updated: February 15, 2023
aerospace-electronics

There is extraordinarily little room for mistakes in the Aerospace mechanism because if any fault happens in space, it is too far for scientists to reach for its retrieval. And as most aerospace machines are electronic devices, some extra attention you have to put in to ensure the efficiency of the PCB Assembly of each electrical aerospace tool.

From standard to the reliability, security in every aspect has to be ten out of ten in space-based systems. To provide that as a manufacturer, you need advanced software, evolved hardware, skilled workers, and many more things, which we discussed in this article to give you a complete guide. So, check it out to know what you need to develop PCB Assembly & Design for an aerospace electronics exceptional performance.

Basic Features of Aerospace PCB Assembly & Design:

The feature of developing an aerospace electronics PCB assembly & Design is not all similar to any simple electronic PCB, and it needs some strict requirements. Any problem in PCB causes landing problems for aerospace, signal trouble to the Control team, or even premature failure before landing. So, to make a suitable, accurate PCB, the features it requires are-

Durability:

Aerospace is most of the time work in an extended period like from months to year without your direct reach like in the air or a faraway from you. So, if the PCB assembly is not efficient enough to last that much time it will be an unbelievably tough situation to handle. Even a long budget project can break down like a sandcastle due to the short-lived components.

So best to prevent such a tragic situation at the time of manufacturing by applying only the best quality, longevity components in the application. It may seem at a first cost a bit high, but ultimately it saves your fortunes which may require future replacement of the material.

Specific material selection:

The material of the PCB assembly manufacturing has to be extremely specific at the time of aerospace electronic devices. Every specific order of aerospace needs exactly suitable material to fit the need of unique contracts.

Always use high-quality materials in aerospace electronics because it is worked in an extremely sensitive aerodrome. Check everything before delivery, like is it working or not. Make sure the materials are flexible to changes. There are very frequent thermal and electrical changes that happen in space.

Bearing ability of the adverse environment:

PCBs (Printed Circuit Boards) of aerospace have to withstand some adverse environmental conditions like extreme heat, outrageous radiation, or severe pressure.

As it is important to protect the outer part, at the same time, it is also very crucial to safeguard the internal device from the radical thermal surge. Because in the engine, the temperature is even more than thousands of degrees which can barely be overcome by ordinary materials. And Another cause of the hazardous environment is the rapid change of different layers of the atmosphere when launching into space as the engine is mostly made of electronic devices. Hence, the PCB’s substance also has to bear such heat.

Testing after manufacturing:

After the PCB assembly manufacturing, you have to check and double-check by thoroughly testing by following the right protocol of inspection. To assure the quality and proficiency of the product delivery, testing is especially important. Because if it fails to work in the testing period, it can be replaced, but if it ceases to function in space, there will not be any second chance to recover.

In testing, you have to primarily consider thermal testing. Vibration testing is another important testing also. Except that internal testing like security testing, quality testing also has to examine.

Risk factors:

Nothing is flawless; besides all testing and examining, there are always some risks present in every field. But in aerospace divorce, you can’t take a risk by any chance. So always tie up with this manufacturer who has good reputation certified skills and has a good public review. Always inquiries about the company before making any contract.

Some points you have to keep in mind at the time of developing aerospace devices:

Here, we are sharing some special points you have to keep in mind to develop the best aerospace device –

  • Choose only the PCB Assembly, which is the suit best according to your demand, standard.
  • Go for the manufacturer you provide updated application, software, hardware, etc.
  • Always prefer quality first. The substandard quality is the root of any failure in the future if it happens.
  • Try to choose easily available PCB components and testify to every component before final purchasing.

Conclusion:
We hope the upper given guideline will help you in choosing the best aerospace PCB Assembly & Design and able to meet all your expectations on your dream project.

At Technotronix, we have over 4 decades of experience in providing PCB industrial solutions. We are therefore well-poised to understand the various issues than plague the industry and how robust testing can help overcome these issues. Our PCB manufacturing facilities hold extensive number of certifications and licenses to meet complete turnkey PCB aerospace solutions. For your any kind of requirements, Get a quick PCB assembly quote.