Printed circuit board assembly, also known as [stuffing" or [populating the bare printed circuit board" is quite an intricate process involving many different phases.
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Why should PCB assembly start with Prototype PCB assembly?
Some design engineers choose to go straight to production after designing and manufacturing a PCB; this, however, is not wise. There are many issues that may arise in the many stages of fabrication, assembly, and testing. Here is why it is important to start with low quantity prototype assembly:
Cost – Prototype assembly of your first prototypes can lead you to discover ways to reduce costs in manufacturing and assembly of your circuit board; plus, mass producing a design with flaws can cost a fortune.
Discover Design Flaws – PCB prototypes may help you discover design flaws that can be corrected before your production run.
Proper Testing – Testing ensures proper functioning of your PCB design and reduces the risk of errors prior to production.
How to find the right prototype PCB assembler?
Before embarking on the design and production of a PCB prototype, it is crucial to select the right prototype assembly partner. Here are important questions to make the proper selection:
- Does the PCB assembler internally manufacture the bare printed circuit board?
- Will all or some parts of the manufacturing be sub-contracted to third-party?
- Does the PCB assembler have technical experience and capabilities for your circuit board design requirements?
- Does the assembler have direct and prompt access materials and components needed?
- Can the PCB prototype assembler produce the pieces by the required timeline?
What information does the PCB assembly order need to provide?
Prior to a PCB prototype assembler beginning a new project, the majority will require this relevant information:
- Amount of prototypes needed
- PCB Gerber files
- Bill of Material (BOM) detailing all components
- Precise timeline of prototype turn-around
After receipt of the necessary information, assemblers can review the material and determine if they can properly meet the deadlines and specific execution of the PCB prototype.
Solder Paste – Solder paste is a combination of flux, a chemical created to assist in the bonding and melting of the metal, and small fragments of metal (solder) in order to apply the electronic components to the printed circuit board. The paste is placed on the board in specific places along the board in exact amounts with the use of a Solder Stencil and a paste application machine, automatically. When an automatic machine is not available to you, it must be executed manually and with the utmost precision.
Pick and Place Machine – This machine is essential in an automated printed circuit board assembly process. The machine is programmed to automatically coordinate with complete accuracy the places to precisely mount each electronic component to be soldered to the printed circuit board. These machines are exact and quick. Human pick and place has a much higher potential for errors in addition to being a much slower, more tedious process.
Infrared Reflow – After the precise bonding element (solder paste) is applied to the PCB, the board will be directed to the reflow oven to join the electronic components to the board by melting the solder paste. This [oven" is comprised of many heaters whose main function is to heat the board to a precise temperature and control the level of cooldown as the solder hardens. This process is crucial to the creation of properly functioning electronics. The printed circuit board will run through a series of testing to ensure no issues or short-circuiting nor misalignments have occurred.
Thru-hole PCB Assembly – A method of soldering electronic components in place by hand using drilled holes in the printed circuit board and connecting pads. This technique creates a stronger physical bond of the component to the printed circuit board but is much more time consuming and the cost of the printed circuit board can increase due to the higher volume of drilled holes.
