In the PCB Electronic Assembly world, PCB is widely used and can be considered the most important electronic component because it has the function of integrating all the others in the same electrical circuit.
It contains the determinations of a circuit according to the way the current is traced; in short, an electronic circuit is a set of components grouped on a previously designed plate.
The board design is a document called Gerber file; it is an open ASCII vector format for printed circuit board designs.
It is the standard actually used by the PCB industry software to describe the printed circuit board images: copper layers, solder mask, legend, drill data, etc.
We can compare this format with a photolith in printers, it contains the matrix and design of what the PCB will look like for large-scale manufacturing and subsequent assembly of the PCB.
It is in this assembly that all other components are positioned and soldered, such as sockets, processors, capacitors, resistors, varistors, connectors, terminals, gas spark gap, etc.
A little bit of the History of Electronic Boards
The first PCBs were produced around 1943, according to discoveries, the plates were developed for military purposes initially, due to the vast majority of intelligence systems until then being of great use, the military needed them for their communication radios, to improve the contact in any crucial situation.
Before the development of the PCB, the circuits were composed of the components soldered in their own terminals, this method was known as the spider, due to its own appearance.
Even before any speculation about the plates, the Austrian engineer Paul Eisler was considered the developer of the plates due to some records of his studies; the vast majority of people claim that he was the creator of the system, a little earlier, in 1925 there was one more record on the subject, being that of Charles Ducas.
He believed that if he deposited a little conductive paint on an insulating substrate, he would obtain the phenomenon named “Printed Circuit Board”. After some time, specifically after the Second World War, they started to be used in more common tasks like transistorized systems, and tasks more focused on common systems.
How is PCB Made?
Nowadays, plates are more used in electronic devices, in the construction of integrated circuits, PCBs are very useful, due to their meticulous form of manufacture, previously a principle called a material called phenolate was used., which consists of an insulating plate, the name for which the brand that manufactured the plates was known.
They carry a mixture of phenolic resin with a small touch of shredded paper or sawdust, as after a while the material started to present problems, they were perfected with more resistant and reliable types of materials.
Firstly, a plate with fiberglass and epoxy resin was developed, these plates are a great choice due to the ability to use multiple layers reducing the size of the circuit, there is also the plate that joins with phenolate and fiberglass, and finally, we have the metalcore, the aluminum-based or copper-coated by an insulating material.
The way they are manufactured, on the other hand, begins with the development of an electrical scheme via software, which can perform a simulation of how the circuit will work and the visualization of the plate in 3D.
The software is responsible for generating a document in the form of a drawing, Gerber, which defines the path through which the current will travel, this process was named “trails”.
These trails can be done with only one face, single face, on both sides, that is, a double face or even in internal layers that are called multilayers, which in turn each of these layers are known as a layer.
Types of PCB Electronic Assembly Mounting
There are two types of PCB mounting:
- SMT(Surface Mounting Technology) assembly Assembly using SMD (Surface Mounting Devices) components
- THT(Through Hole Technology) Assembly Assembly using PTH (Pin Through Hole) components
The assembly of PTH PCBs, where the terminals of the components are inserted into holes in the PCB and welded on the opposite side, is generally a manual process. The assembly of SMD PCBs is carried out without the need for holes, the components are positioned millimetrically by machines and welded on the surfaces of the PCB.
SMD needs a more agile and precise assembly, due to the fact that the procedure is performed largely by machines since the components are difficult to be handled by people, as they are of a very small size. The first step in the process is to apply a solder paste using a printer, that is, a printer using a stencil, which is a sheet of metal with precise openings in the places where the paste is to be deposited.
The paste is a chemical composition that serves to fix the component that will be inserted in the plate through the insertion machine, which collects the component from the roll and places it on top of the paste that was deposited on the plate; this is done due to the suction made by compressed air.
The positions where the components are to be deposited are defined in the form of parameters for the machine, through a document almost always in TXT format.
What is Remelting in PCB Assembly?
After the insertion, the next step will be remelting, where the plate will undergo a very high temperature to melt the solder paste and make the connection of the component terminals to the solder area of the plate. And to complete this process, the inspection is carried out.
AOI (Automated Optical Inspection) occurs through programming made with the model plate, to make the comparison with the material produced.
The procedure for assembling PTH PCBs is slightly different, in this assembly, components are manually inserted into the board in cells, stations, or production lines with mats.
The plates are placed on the pallets, then they are placed on the welding machine conveyor, where the plate will gain a layer of welding flux and pass over a wave-shaped tin tank, which will have the purpose of welding the inserted components.
This tank can be composed of two types of solder, with lead-tin or Lead-Free, without lead. Right after going through a cooling period, the plates go through the visual inspection process or even tests.
How to Hire PCB Electronic Assembly Services?
Currently, PCBMAY offers two types of contracts to perform PCB assembly, they are Labor, in this method the customer is responsible for logistics and supplies all the necessary components to supply the assembly line.
The other method, on the other hand, is called TurnKey, where PCBMAY is responsible for all the logistics, supply, storage, and assembly of the PCB, guaranteeing all the components in the assembly line of the boards and their monthly replacement.
The Turn Key method is considered the most advantageous for both sides, especially if the company responsible for the assembly has an infrastructure prepared for the entire process.
Together with PCBMAY, you can choose the best option for your company, since we are a reference in plate assembly. Come pay a visit and get to know our structure.
The assembly of the components is a very important phase for the realization of a PCB, a professional PCB electronic assembly company offers a flexible and fast assembly service able to respond to the request for prototyping of samples, pre-series, and small series in a short time.
How to Request a Fast PCB Electronic Assembly?
With a view to providing increasingly innovative services with high technological content, it is possible to request a fast PCB electronic assembly service which consists in providing complete prototyping in a very short time, including assembly of electronic boards, printed circuits, in a maximum and guaranteed time of 5- 6 working days *.
The intent is to have a single interlocutor for the customer who takes care of the total management of fast sampling in order to avoid continuous contact (with the waste of time and problems perhaps of understanding or interpretation) between customer – producer of circuit board – assembler.
Therefore, starting from the initial cad files, PCB direct Lab takes care of the execution of all the fast ** sampling of the electronic board (usually from 2 boards up to a maximum of 15-20 printed circuits), starting from the sizing and execution of the quadrotor, the management of the files for the execution of the foil, the programming and the Set-up of the SMT lines with relative assembly and finally the completion of the Pth part (manual assembly if necessary or if required).
For the procurement of components, all that is available from the warehouse is used.
With regard to the slightly more specific components, we turn to the fast delivery service. Finally, the “less manageable” things (components that are difficult to find for various reasons such as dimensions, design, cost or specificity, etc.), will be provided by the customer.
Always Looking for 100% Quality in PCB Electronic Assembly
Because the quality of your products is important, a professional PCB electronic assembly company develops quality control processes that guarantee you peace of mind.
They must be committed to offering you products that follow very strict measures, in addition to being subject to regular checks. This guarantees you 100% respected quality.
We take seriously the importance of delivering functional products to our customers that meet standards specified by industry and demanded by customers.
Major Assembly Services
- SMT – Automated Assembly
- THT – Through hole technology (lead-free Wave solder)
- A mix of SMT and THT
- Cable harness
- Turnkey solution with tests and enclosure.
A professional PCB assembly company understands that the task of assembling electronic boards currently demands quality work with immediate results, so we offer a quick response time in all quotes requested.
PCB electronic assembly team and test engineers can meet your assembly needs in just 7 days, thanks to our hardworking ability and customer service philosophy.
They aim to offer you the best service by assembling the highest quality PCB products which meet customer’s requirement at all times. We offer innovative manufacturing solutions while maintaining an interaction with our customers that enables us to continuously improve throughout the life of the product.
Verification of Card Mounting, Inspection, and Testing
With automated optical inspection (AOI), subjectivity is eliminated and the variability associated with manual inspection.
In addition to AOI, PCB electronic assembly technicians are highly qualified to detect the slightest imperfection.
Our technicians are trained to perform in-circuit testing and provide the highest quality plate testing.
The electronics industry is becoming more complex than ever. As NPI increases, so does product variation and switching.
We meet the industry’s needs for increased productivity and utilization and aim to provide a complete SMT manufacturing solution that overcomes today’s complex electronic component production.
Take Productivity to New Heights
PCBMAY smart factory board assembly products give manufacturers greater flexibility, complete planning visibility, thorough component tracking, efficient switching, automatic replenishment, and intelligent component storage solutions. To
We help you increase the usage rate several times without increasing the number of staff by deeply understanding the problems faced in production and proposing solutions that integrate various products to solve them.
Quality Control by Data
Today’s factories are full of data and are producing more and more data every moment. Being able to collect, correlates, and analyze this data wisely is the greatest asset that can help improve quality control.
Close the Productivity Gap
Even when operators and machines are at full capacity, there are benefits that can be generated. By strengthening the interface and realizing smart interaction, it is possible to create even greater value with existing resources.
Flexibility Throughout the Factory
Flexibility is not only about proper equipment production, but also about helping to shorten cycles and developing the latest applications. It creates a new cycle in which suppliers, customers, and partners work together to innovate.