Understanding the Different Types of Electronic Assembly Processes

Understanding the Different Types of Electronic Assembly Processes

Printed circuit boards (PCBs) are critical in producing nearly every modern electronic device, from smartphones and personal computers to the industrial machinery used in manufacturing facilities. Depending on the type of PCB and its end application, there are a few main types of electronic assembly processes manufacturers can choose from. Regardless of the assembly method, all PCBs must undergo rigorous quality assurance checks before being installed in their final products.

Learn more about each of these PCB assembly processes and the quality assurance measures necessary to produce high-quality PCBs.

Types of PCB Assembly Processes

All electronic assembly processes involve electrical components being mounted and connected on a PCB to create a functional product. However, each assembly process offers distinct advantages depending on the PCB’s intended application.

Here is a breakdown of the different types of assembly processes and their most common use cases.

Surface Mount Technology (SMT) Assembly

Surface mount technology (SMT) has become the standard process for modern PCB assembly. In this basic process, the components are mounted directly onto the surface of the PCB without the need to drill holes. This allows for smaller, more efficient designs and is ideal for high-volume, automated production. Common applications for SMT assembly include PCBs for:

• Smartphones
• Computers
• Home appliances
• Industrial equipment

Through-Hole Technology (THT) Assembly

Through-hole assembly used to be the go-to method for mounting components on PCBs. In this process, component leads are inserted into pre-drilled holes on the board and soldered in place. Even though SMT is currently considered the industry standard, there are still some use cases for through-hole assembly, including:

• Large transformers
• Electrolytic capacitors
• Connectors (e.g., headers, jacks, plugs)
• Diodes and transistors

Rigid-Flex Printed Circuit Board Assembly

Rigid-flex PCB assembly combines the durability of rigid boards with the movability of more flexible substrates. These boards are built with multiple layers of flexible circuit materials that are connected internally or externally to one or more rigid boards. This results in a versatile PCB that can be folded or bent during installation, making it ideal for applications where space is limited. Common applications for rigid-flex PCBs include:

• Wearable devices
• Laptop computers
• Smartphones
• Automobiles
• Testing equipment

Mixed Assembly

As the name implies, mixed assembly combines assembly techniques, particularly SMT and THT. Mixed assembly combines the features and advantages of these techniques, such as soldering and secure through-hole mounting, to ensure that all components are mounted securely. Common applications include:

• LED lighting
• Sensor boards
• Server boards
• Video processing equipment

Ball Grid Array (BGA) Assembly

Ball grid array (BGA) assembly is an advanced technique used primarily for mounting microprocessors and other integrated circuits. The chip is mounted to the PCB using a grid of small solder balls on the bottom of the package. This allows for more connection points than traditional methods, improving the performance and reliability of high-speed electronics, such as:

• Smartphones
• Computers

Quality Assurance Practices for Electronic Assembly

Verifying quality at every stage of the PCB assembly process is essential. Without rigorous quality assurance (QA) practices in place, even the best-designed PCB can fail. This can lead to devastating setbacks and a significant loss of time and money.

Here are some key QA practices to look for when choosing a reliable PCB assembly partner:

• Certifications: Look for ISO, AS9100, and ITAR certifications that demonstrate a manufacturer follows strict quality control practices and meets industry safety standards.
• Experience: Manufacturers with an established reputation in your industry are likely to produce the best results for even the most complex PCB assemblies.
• Inspections and rigorous testing: Effective QA inspection and testing combine human oversight with automated systems to catch defects and ensure the final product is ready for its end-use environment.

PCB Assembly Services From Circuit Pak

The complex process of PCB assembly involves choosing the right method based on the project’s needs while maintaining the highest levels of quality throughout production. Partnering with a trusted manufacturer that follows strict quality assurance practices is essential to your project’s long-term success.

Founded in 1983, Circuit Pak is an experienced contract manufacturer and assembly provider for PCBs. Equipped with advanced automated production lines, we offer all the main types of PCB assembly techniques, including SMT, THT, mixed, and BGA assembly. We perform all production and quality control processes from our 50,000-square-foot ESD-controlled facility in Dayton, Ohio.

Request a quote to learn how we can help bring your next project to life.

Navigating the Complexities of Aerospace PCB Assembly

The aerospace industry depends on quality-engineered printed circuit board (PCB) assemblies to ensure reliable equipment performance in critical applications. Aerospace PCB assembly services help manufacturers achieve this goal. Involving the careful design of a PCB prior to manufacturing it, these services produce quality components virtually free of flaws.

Compared to traditional assembly services for PCBs, the precision of aerospace PCB assembly cuts down on parts rework and replacement, labor costs, and production time. Alternately, high-performance aerospace PCB assemblies support efficient, continuous operations and can enhance your company’s reputation amongst satisfied customers. Read on to learn more about the struggles the aerospace industry encounters and how PCB assembly from a trusted service provider can elevate your products.

Overcoming the Challenges in Aerospace PCB Assembly

Aerospace industry manufacturers face both regulatory and physical challenges in creating components for air- and spacecraft, requiring durable PCB assemblies that offer dependable performance even under harsh conditions.

Compliance With Stringent Industry Standards

Given their mission-critical applications, aerospace PCB assemblies have to comply with strict quality and safety standards. Meeting these exacting industry requirements helps guarantee that an assembly, down to its very last part and regardless of its environment, will achieve optimal performance in aerospace applications.

Assembly Weight

PCB assemblies for the aerospace industry must adequately balance durable strength with lightweight construction. This helps keep costs down while increasing fuel efficiency as well as payload capacity for passengers and cargo.

Vibrations

Aerospace PCB assemblies and their parts are sensitive components, meaning that the vibrations they experience during flight can impact their functionality or damage them. Often, such damage occurs at soldered joints as they weaken or fracture, affecting circuitry as well as navigation and control systems or disrupting connections and communications.

Fluctuating Temperatures

Aerospace applications subject their equipment to everything from rapid altitude changes to harsh environmental conditions. Experiencing extreme heat and cold — sometimes both within a short timeframe — air- and spacecraft PCB assemblies must reliably withstand intense temperatures and varying thermal conditions without sacrificing performance.

Addressing Aerospace Industry Challenges

Manufacturers employ various techniques to surmount the difficulties inherent to production for the aerospace sector. This can range from copper plating to enhance heat dissipation in a component to generating high-temperature laminates that help assemblies survive exposure to extreme heat. Component miniaturization is another solution that’s becoming increasingly popular as miniaturized parts help reduce weight while delivering uncompromising durability and performance.

Applications and Benefits of Aerospace PCB Manufacturing and Assembly

Aerospace PCB assembly is critical to making parts for the following systems and technologies:

Regardless of the application, high-quality assemblies are extremely advantageous in the aerospace sector. In addition to offering benefits like impact and vibration resistance that other industries might require, aerospace PCB assemblies also have to hold up against high-speed motion, extreme and changing temperatures and pressures, radioactivity, and more. From handling takeoff, in-flight, and landing conditions in aircraft to harsh outer space environments in space vessels, aerospace PCB assemblies retain their integrity to be fully operational.

Precision Assembly for Complex Electronics

The accuracy of precision-engineered aerospace assemblies helps ensure lasting durability, continued operations, and proper fit within existing equipment while making complex systems and designs possible. Through precise soldering, manufacturers can construct high-performance PCBs and reliable circuitry to not only promote maximal performance in demanding applications but also prevent accidents and fatalities.

Continued Operation in Challenging Environments

Companies manufacturing PCBs engineer high-temperature laminate substrates using materials like aluminum and copper, allowing a PCB to withstand excessive heat. They can also incorporate specialty materials into these substrates for radiation mitigation.

Planning for and Handling Equipment Failure

Proper functionality and safety are of paramount concern in the aerospace industry. While stringent quality control and testing practices throughout PCB assembly production will lessen the chance of part failure, manufacturers for this market must design products and systems with reliable backup options in mind. The goal is to minimize the impact of potential component failure by creating system redundancy through PCB assembly. In this way, companies better ensure smooth, ongoing operations when a part inevitably fails.

Achieving Aerospace PCB Assembly With Circuit Pak

At Circuit Pak, Inc., we understand the challenges facing our customers in the aerospace industry. Since 1983, we’ve supported a diverse client base as a leading provider of trusted PCB assembly, kitting, quality control, and related value-added services. Our team is experienced in thru-hole as well as surface mount assembly, placing approximately 80,000 parts per hour without sacrificing quality, consistency, or assembly integrity.

Be it simple or complex, Circuit Pak can support your project with complete PCB assembly solutions. Contact us to speak with an expert about our capabilities for your aerospace application, or request a quote today.