Surface Mount - The Most Preferred PCB Assembly Method

Surface mount technology is one of the most preferred methods of placing or mounting components on printed circuit boards. It has greatly replaced through-hole technology and gave electronic designers and circuit board assemblers an alternative and more reliable means to fit components into the circuit board. In some cases, surface mount technology may be used in conjunction with through-hole technology, especially when certain components are unsuitable for surface mounting, as in the case of heat-sinked power semiconductors and large transformers.

There are various reasons to prefer surface mount to conventional PCB assembly methods. One of its advantages is its versatility and reliability when it comes to linking different individual parts in a single electronics system. This results in higher productivity, minimal downtime, and improved product quality. With the surface mount technology, you can manufacture smaller and more components for improved performance, especially in smaller hand-held devices.

Components that are made using surface mount technology are smaller and enable higher component density on printed circuit boards. With surface mount, automated assembly can be faster and seamless because it allows more than a single component to be placed on the board per hour. Small errors can be corrected automatically to reduce downtime. SMTs are better in mechanical performance, too, especially under situations where shaking or vibrations are common.

Experienced and reputable electronic design and circuit board assembly companies use surface mount technology to assemble printed circuit boards. They use high-end machinery—such as high-speed surface mount lines—to manufacture a large amount of various electronic assemblies. At the same time, they utilize the services of IPC certified manufacturing technicians to manually assemble other additional parts that machines may not be able to assemble or place.

Five Ways to Build a Prototype PCB Assembly

A prototype PCB assembly can give you a clear idea of how your device looks and functions. Printed circuit boards electronically connect and mechanically support electronic components using pads, conductive tracks, and other features, which are etched from copper sheets and laminated on a non-conductive substrate. Here are ways to build prototype PCB assemblies:

1. Through-hole – This form of mounting technology uses component leads that are placed into drilled holes on a printed circuit board. This was the standard until surface mount technology became available in the 1980s. Some electronic design companies still use through-hole mounting with SMT on certain projects.

2. Surface mount technology – SMT can be a cost effective means to build a printed circuit board because it provides smaller and compact components for improved performance. Surface mount is fully automated, and minor errors can be corrected with ease, resulting in more savings in terms of time and costs to develop an effective PCB.

3. Rapid prototyping – This method lets designers create a more tangible prototype of their design. The resulting prototypes are superior to CAD or 3D models. Through rapid prototyping, changes and improvements can easily be made to the design of a PCB assembly before it is finalized and sent into actual production.

4. Module assembly – A work cell can be developed and optimized to suit your production rate and volume requirements. Reputable manufacturing engineers can introduce flexible robotics into the work cell for a more cost-effective production process. This way, it is possible to make complex control systems with multiple mechanical components and circuit board assemblies.

5. Soldering – Once the parts have been attached to the board, the assembly is passed through a soldering machine. Some boards may go through a wave soldering machine as long as there is no solder paste on the board. Newer soldering techniques rely on the reflow method, especially when a solder paste is used.

Search Online For Your Next Printed Circuit Board Assembly Project

Printed circuit boards have become increasingly popular over the years where smaller and more versatile devices and gadgets are being manufactured. Hiring a circuit board assembly service will help you accomplish your next printed circuit board assembly project cost-effectively and with ease. The best way to search for this type of service is to go online and look up reputable companies specializing in it. Electronic design companies have the experience to cater to a wide range of clients from different industries, including military and aerospace, telecommunications, medical, and automotive markets.

It can be practical to work with a printed circuit board assembly supplier, even when you already have a working prototype. PCB assembly specialists can explore your design and test it, and recommend ideas to further improve it or ensure its reliability and efficiency. With their help, you can be sure that you are making a PCB that can help meet the goals of your project. Look for specialists that are TS 16949 and ISO 9001 certified, and make sure they comply to ISO 13485 and AS 9100.

A full service turnkey supplier of custom electronics will ensure a high-quality printed circuit board assembly for your project. They can design and prototype your new product and assist in full scale production. Consider a supplier that has, at least, three decades of experience in electronic design and circuit board assembly services. Longevity is a good indicator of a supplier's reputation, reliability, and its ability to form long term relationships with their clients.

Look for a company that has its state of the art manufacturing, assembly, and testing facility. Verify their facilities. Consider a company that has an automated stockroom, BGA X-ray, Flex-SMT lines with in-line automated 3D optical inspection, and automated selective soldering. Their staff must be trained to IPC-A-610 class 2 and 3, and IPC J-STD-001 class 2 and 3.

Know the Advantages of SMT PCB Assemblies

Circuit boards produced with surface mounting technologies have dramatically changed electronics manufacturing. Surface mount technology is one of the most advanced ways to manufacture electronic circuits where the components are placed or placed directly on the surface of PCBs (printed circuit boards). It has become a better alternative to the through-hole technology method of fitting wire lead components into the holes in a circuit board. There are many advantages to using SMT PCB assemblies. Here are some of them:

• It can be used with through-hole technology – Both SMT and through-hole production methods can be done on the same board. SMT can be used on components that are unsuitable for surface mounting, like heat sinked power semiconductors and large transformers.
  
  
• Cost-effective production – Surface mount technology can be a more cost-effective way to produce printed circuit boards because of the smaller size of its components. SMT components are typically smaller than through-hole versions due to either the absence of leads or smaller leads. It can have leads in different styles or short pins, a matrix of BGAs or solder balls, terminations on the component body, or flat contacts.

• Suitable for smaller devices – The ease of construction and their greater component density make them more ideal for devices that are smaller. SMT PCB assemblies enable you to make feature-packed smaller devices at lower prices.

• Automated assembly – SMT PCB assemblies can work with some placement machines for a faster and simpler way to assemble your device. Certain machines can place over 136,000 components per hour, and small errors in placement are automatically corrected as the molten solder's surface tension pulls the components to align them with solder pads.
  
  
• Versatility – The components can easily be placed on either or both sides of a circuit board. SMTs offer lower inductance and resistance at a connection, resulting in fewer RF signal effects, as well as more predictable and better performance at high frequencies.

• Better performance – In addition to minimizing the effects of RF signals, SMT PCB assemblies offer lower radiated emissions because of the smaller lead inductance and smaller radiation loop area.

• You can have them made – Look for a reputable company that specializes in circuit board assembly services and electronic design to a wide range of industries. This way, you can count on a reliable turnkey supplier to customize SMT PCB assemblies for your needs. Consider a company that has more than three decades of experience in contract electronic manufacturing.

Basics of Printed Circuit Board Assembly

Printed circuit board assembly is a multi-step processes that involves the use of either or both through-hole and surface mount technologies/assembly techniques. During this process, the bare board is assembled and populated with all the electronic components necessary to create a functional PCA or printed circuit assembly (also PCBA or printed circuit board assembly).

In through-hole assembly, component leads are put in place by inserting contacts through holes, while surface-mount assembly involves gluing of components on pads or lands attached to the surface of the PCB. After assembly, component leads are then mechanically fixed and electrically connected to the board through soldering.

Different soldering techniques are also used to secure and attach components to a printed circuit board. In high-volume production, soldering is usually done using SMT (Surface Mount) placement machines and reflow ovens, which allow for bulk wave soldering. Skilled technicians on the other hand, have the ability to solder even the tiniest parts by hand using only tweezers, a fine tip soldering iron, and a special microscope, such as in the case of 0201 packages, which are a wee 0.02 by 0.01-inches in size. Manual soldering, however are only practical for small-volume prototypes as they can be quite time-consuming and labor intensive, although they do offer extreme precision. Some parts and components, on the other hand may be extremely difficult or impossible to solder by hand.

In many cases, through-hole and surface mount techniques and construction must be performed and combined in one assembly as some components might only be available in surface-mount packages and others in through-hole. Another possible reason why both methods are required is when components require additional strength or might be prone to physical stress, for which through-hole mounting can provide added security. When components are expected to go undisturbed or untouched, surface mount techniques are preferred because SMT packages take up less space.