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A Comprehensive Guide to PCB Material Selection

 

Author Archives: Circuit Pak, Inc.

  1. A Comprehensive Guide to PCB Material Selection

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    Printed circuit boards (PCBs) play an essential role in a wide range of modern electronics. Whether used in simple consumer gadgets or complex industrial equipment, choosing the right PCB material is critical in ensuring performance and reliability. In this guide, we’ll cover the basics of PCB materials and highlight the various options available to aid your selection.

    What Is PCB Material?

    PCB materials refer to the substances used to assemble the numerous layers of a PCB. These materials serve as a foundation for the mechanical and electrical properties of the PCB, ensuring adequate durability and functionality. PCB materials can be broken down into four main categories:

    • Substrate Materials
    • Dielectric Materials
    • Conductive Materials
    • Solder Mask Materials

    Choosing the Right PCB Material for Your Application

    When choosing the right PCB materials, it’s important to consider the specific requirements of your application. Key factors to consider include:

    • Electrical Performance: Consider the electrical requirements of your PCB, such as current, voltage, and frequency.
    • Thermal Performance: Consider how much heat your PCB will produce and how that heat will need to be dissipated.
    • Mechanical Performance: Another key consideration is mechanical performance. Requirements for strength, weight, and rigidity will play an important role in material selection.
    • Cost: Factor in your available budget for PCB production and how this will influence material choice.

    Types of PCB Material

    Common PCB material options include:

    FR-4

    FR-4, which stands for Flame Retardant 4, is the most common PCB material used throughout the electronics industry. This composite material consists of woven fiberglass cloth, which has been impregnated with epoxy resin to create a unique balance of electrical insulation, mechanical strength, and thermal stability.

    FR-4 offers the following benefits:

    • Ideal Electrical Properties: The electrical properties of FR-4 make it ideal for diverse applications. Its typical dielectric constant (Dk) is approximately 4.2, and its dissipation factor (Df) ranges from around 0.015 to 0.025 at 1 GHz. These properties can vary based on the material’s formulation and manufacturing process.
    • Good Thermal Properties: FR-4 has a glass transition temperature (Tg) of approximately 130 °C to 180 °C, which is a sufficient range for typical electronic uses. However, applications exposed to high temperatures or significant thermal cycling may require alternative materials with higher Tg values.
    • Cost-Effective: FR-4 is a cost-effective material that is more readily available compared to alternative PCB materials.
    • Compatibility: FR-4 is a popular choice due to its compatibility with conventional PCB manufacturing processes.

    High-Temperature Materials

    High-temperature PCB materials can withstand thermal cycling and higher temperatures, making them a good choice for applications where traditional materials may not perform as needed. Common high-temperature PCB materials include:

    Polyimide

    This high-performance polymer offers excellent mechanical strength, thermal stability, and chemical resistance. It has a Tg of approximately 280 °C to 350 °C, allowing it to maintain its electrical and mechanical properties even at elevated temperatures. This material also has a low coefficient of thermal expansion (CTE), reducing the risk of warping and delamination during thermal cycling. It has a Dk of about 3.2 to 3.6 and a Df of about 0.002 to 0.003 at 1 GHz, making it ideal for applications exposed to high frequencies.

    Ceramic-Based Substrates

    Ceramic PCB materials, like aluminum nitride (AlN) and alumina (Al203), provide high-temperature stability, great thermal conductivity, and low CTE. The high thermal conductivity of these materials lowers the risk of component failure due to overheating. Ceramic PCB materials also feature low dielectric constants, making them well-suited for high-frequency applications.

    Rogers

    Rogers PCB materials are high-performance materials constructed from a combination of ceramic and epoxy. They are known for their high dielectric constant, low water absorption, good thermal conductivity, and low loss tangent.

    These materials are named after Rogers Corporation, a manufacturer of high-performance engineered materials. Rogers PCB materials are produced by laminating several layers of specialized raw materials together. They are typically used in high-frequency and high-speed applications requiring a high degree of thermal management, signal integrity, and reliability. Common applications for these materials include:

    • Radio Frequency Applications
    • High-Speed Electronic Designs
    • Commercial Microwaves
    • Power Amplifiers
    • RF Identification Tags
    • Sensors
    • Automotive Radars
    • Cellular Phones
    • Wireless Networks
    • Satellite Communications

    PCB Assembly Services from Circuit Pak, Inc.

    Choosing the right materials is key is assembling high-performance, reliable PCBs. At Circuit Pak, we offer high-quality PCB assembly, kitting, and quality control services. As a leading provider of PCB assemblies and value-added services, we have the expertise to deliver complete PCB solutions for even the most demanding projects.

    For more information about the various PCB materials, or to get started on your next PCB assembly project, contact us or request a quote today.

  2. Streamlining PCB Assembly with Efficient Kitting Processes

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    PCB Kitting is an inventory management strategy that can help businesses increase their revenue and improve customer satisfaction. It involves grouping all necessary parts for the specific assembly in one kit, so assemblers can access everything they need in one place. This results in enhanced workflows and higher production yields, making it ideal for any PCB manufacturer looking to improve their operations. Below, we’ll break the process down into manageable steps and share some of the top benefits kitting solutions offer.

    Steps for Implementing an Efficient Kitting Process

    Taking a systematic approach to kitting will help ensure its success. Here are the key steps to take when establishing an efficient kitting process for PCB assembly:

    1. Identify your Purpose: Clarify your kitting program’s primary goal, whether it’s reducing storage or speeding up assembly, to determine how the kits should be structured.
    2. Analyze Inventory Data: This can help you decide which parts to include. Frequently used components and those with high wear and tear tend to be good candidates.
    3. Select Components: Pick the components that will go in each kit based on usage patterns and kitting needs, whether they are tools or specific parts.
    4. Standardize Kits: Establish standardized kits based on everyday tasks to maintain consistency and reduce complexity. Going too far with customization can increase costs and slow down production.
    5. Create a Bill of Materials (BOM): Documenting kit components simplifies reordering and keeps things consistent. Items to list include tracking metrics like part numbers, descriptions, and quantities.
    6. Engage Suppliers: Communicating regularly with suppliers is critical to ensure timely availability of kit components. This includes negotiating pricing, terms, and quality metrics.
    7. Vendor-Managed Inventory (VMI): Leveraging VMI allows suppliers to monitor and manage inventory levels. This arrangement minimizes stockouts and enables on-time kit restocking.
    8. Choose Packaging: Proper packaging protects components and ensures easy handling. For example, warehouse kits may require a less costly option, such as white boxes with basic labels.
    9. Label Kits: Clear, accurate labeling—ideally with barcodes—facilitates efficient tracking and retrieval throughout the kitting process and broader supply chain and lowers assembly errors.

    Benefits of Kitting for PCB Assembly

    Optimizing kitting processes for PCB assembly comes with numerous benefits:

    • Space-Saving: Grouping components into kits reduces storage, making more room for production. This can be particularly valuable in lean manufacturing settings.
    • Bolstering Productivity: For companies that fulfill their orders in-house, kitting saves time and labor, allowing them to focus on high-priority tasks like product development and quality control.
    • Increasing Volume and Speeding Up Assembly: Kitting facilitates faster assembly, as workers no longer need to pull each component individually. By preparing and organizing parts in advance, manufacturers can process orders faster and at higher volumes.

    PCB Assembly and Kitting Options with Circuit Pak

    At Circuit Pak, we understand the value of a streamlined kitting process. Our clients can choose between two main kitting options for PCB assembly:

    1. Supply Your Own Kit: This choice is ideal for customers with specific requirements for particular assembly projects.
    2. Circuit Pak-Managed Kitting: Customers can benefit from our expertise in sourcing, organizing, and delivering high-quality components for seamless assembly.

    We have been a trusted partner in the PCB assembly industry since our founding in 1983. We provide end-to-end solutions that include quality control and tailored services. With our kitting services, you can be confident in reliable, efficient assembly support that meets even the most complex project needs.

    Do you need kitting support for your next PCB project? Get in touch with Circuit Pak today to get started on your assembly solution or to learn more about our kitting options.

  3. Everything You Need To Know About SPI Solder Paste Inspection

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    One step in the PCB assembly process is applying solder paste to the boards. Deposition is either integrated into the pick-and-place machine or done with stand-alone equipment. The paste is deposited in specific locations and amounts as guided by a stencil so that the board can then be populated with components like resistors, capacitors, application-specific integrated circuits (i.e. AISCs or chips), and EMI shields.

    If components are placed incorrectly, the circuit may not function reliably or as intended. What’s more, if the solder paste is not located correctly, it becomes difficult or impossible to solder the components in the right places. Improper solder paste deposition can prevent components from being fully secured to the board.

    At Circuit Pak, we provide optical solder paste inspection (SPI) as part of our PCB assembly services. Keep reading to learn what it is, why it’s important, and how it works.

    What Is Solder Paste Inspection (SPI)?

    SPI is the process of verifying that solder paste has been applied correctly to a PCB. Carefully prepared stencils are used to align and apply the paste; however, there is always a chance for error. Inspection can catch these errors early in the assembly process so they can be corrected before an entire batch is affected.

    SPI checks these things:

    • Presence or absence of solder in specific locations
    • Deposit dimensions: height, volume, surface area
    • Composition of paste
    • Placement
    • Stencil offsets
    • Surface defects

    The machine uses optical technology to measure the solder paste deposits, sensing the height, width, and layout of each solder line. If the detected solder paste is within parameters, the PCB passes inspection and continues through assembly. If not, the point(s) of failure are identified so the deposition process can be adjusted.

    Benefits of Solder Paste Inspection (SPI)

    SPI catches errors before they affect soldered components and the entire batch of PCBs. It has several benefits in the PCB assembly process:

    1. Defect Prevention. It is always preferable to identify and resolve problems as early as possible to avoid scrap or rework later. SPI finds places where solder paste was applied incorrectly or not at all so they can be corrected. This may involve refining the stencil, adjusting paste composition, part alignment, or other changes.
    2. Reliability. SPI is a positive identification process, so in addition to identifying problems, it also verifies when solder paste is applied correctly. This acts as a “green-light” for further assembly and minimizes the risk of disruptions to production.
    3. Cost-Effective Operations. Finding and fixing errors and keeping defective PCBs out of the assembly line results in less waste, less time spent reworking components, and less money for supplies and labor.

    How Does Solder Paste Inspection (SPI) Work?

    SPI inspection uses 3D imaging software and computer algorithms to compare the PCB being inspected to accurate reference images and data. In this way, it can detect inconsistencies in soldering paste, unexpected or missing placement of paste, and incorrect dimensions of paste deposits. SPI tools can also detect physical damage, scratches, and stains on the PCB surface.

    Industry 4.0 and SPI

    SPI technology is continually improving. AI and machine learning tools can detect minute variations in paste deposits in even highly complex PCB layouts. As optics technology advances, scans become more accurate and make it easier to identify problems, troubleshoot, and resolve them quickly.

    Industry 4.0 makes it possible to connect all the machines in an assembly line and computers with inspection and diagnostic software in a secure network. This creates an efficient feedback loop to find and define specific problems, and then make adjustments at the point of need in nearly real-time.

    Choose Solder Paste Inspection Services From Circuit Pak

    At Circuit Pak, we’re committed to quality at every point of the PCB assembly process. With SPI services, we help ensure finished PCBs are built correctly and function reliably and as intended. Contact us to learn more about our PCB assembly services, or to request a quote.

  4. Understanding the Different Types of Electronic Assembly Processes

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    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.

  5. Navigating the Complexities of Aerospace PCB Assembly

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    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:

    • Battery management systems (BMSs)
    • Communication, navigation, and control systems
    • Aviation instrumentation
    • Radar installations
    • Satellite equipment
    • Power and thermal sensors

    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.

  6. The Benefits of Outsourcing to an Electronic Contract Manufacturer

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    While many businesses have great product ideas, they do not always have the manufacturing capabilities to bring their components to market or meet growing demand. In these situations, outsourcing manufacturing to a skilled contract manufacturer can deliver cost savings, improved product quality, and many other benefits. Electronic contract manufacturers help this demanding industry create quality products more efficiently. This guide will explain what contract manufacturing is and the unique advantages of outsourcing.

    What Is Contract Manufacturing and Outsourcing?

    Manufacturing electronic products requires investing in a production facility, advanced equipment, and skilled employees, all while navigating complex logistical issues. Contract manufacturing is an alternative solution to these requirements. It is a form of outsourcing where a business or product designer contracts with an experienced manufacturer to have products built on their behalf.

    While the contracted manufacturing company handles the production process, your company is free to focus on the aspects of running your business, like customer service, marketing, and innovation. Companies of all sizes require electronic contract manufacturing services to scale their products according to demand, lower operational costs, and improve the efficiency of their operations.

    The Benefits of Outsourcing to an Electronic Contract Manufacturer

    Outsourcing your production to a skilled contract manufacturer offers many benefits. From reducing labor costs to improving product quality, the right partner can take your business to the next level. Below, we’ll cover the biggest benefits of outsourcing manufacturing to a well-qualified contract manufacturer.

    Reducing Fixed and Labor Costs

    Many electronics manufacturers reach a point where their facility is no longer able to keep up with demand or requires new equipment to improve the production process. However, expanding to a secondary location or making updates to your existing facility can be costly. Hiring and training additional staff is another significant expense.

    By partnering with a contract manufacturer instead, you can avoid all of these costs and mitigate risk. Manufacturers like Circuit Pak already have large, state-of-the-art factories and well-trained staff that are ready to take on your projects.

    Increasing Flexibility and Scalability

    Manufacturing any product not only requires a large investment of time and money but also careful infrastructure planning. You’ll need to accurately predict the future demand for your products and ensure your facility will be able to keep up. However, navigating demand fluctuations is challenging. In times of high demand, you may not have enough resources or capacity, while low-demand periods can make it difficult to cover your fixed costs.

    By outsourcing manufacturing, you can eliminate these concerns. Partners like Circuit Pak can effortlessly accommodate changes in demand and scale your business as needed. If you’re not using a contract manufacturer as your primary manufacturer, you can still establish a contract partnership for handling overflow. Either method will allow you to stay agile while keeping costs low.

    Improving Quality and Efficiency

    Electronic contract manufacturers like Circuit Pak are experienced specialists. Our team not only has over 40 years of electronic manufacturing experience but also an expansive 50,000-square-foot facility equipped with high-speed surface mount lines for automated assembly. Partnering with us grants you access to industry-leading expertise, without having to hire and train staff yourself. We can place up to 90,000 parts per hour, and our rigorous quality control procedures ensure that every product is built to the highest possible quality standards.

    Innovate with Technical Expertise and Collaboration

    One of the most significant advantages of outsourcing manufacturing is the technical expertise your company will benefit from. While your business has to manage many functions, a contract manufacturer devotes all its energy to perfecting the manufacturing process. Contract manufacturing partners offer invaluable insights that can help with the following:

    • Improve your designs for manufacturability
    • Streamline production
    • Source best-in-class materials

    Collaborating with your contract manufacturer can help your business innovate better products and services for your customers.

    Electronic Contract Manufacturing With Circuit Pak

    Outsourcing your electronics manufacturing is a cost-effective way to benefit from industry-leading expertise while scaling your operations. At Circuit Pak, our staff handles projects of any size or complexity with both speed and precision. We are ISO 9001:2015 certified and use the most advanced assembly methods to produce unrivaled product quality at a competitive price. To discuss your manufacturing needs, request a quote today.

  7. Designing for Manufacturability: Through-Hole vs. Surface Mount

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    Designing for manufacturability (DFM) optimizes the design, materials, and manufacturing process of a product so that it can be produced as efficiently and cost-effectively as possible. For printed circuit boards (PCBs), a key DFM consideration is how the board is assembled, whether it’s with through-hole technology (THT) or surface mount technology (SMT). Here, we take a closer look at through-hole assembly and surface mount assembly options to help you choose the best production method for your PCB assembly.

    Through-Hole Technology (THT)

    Through-hole technology (THT) or through-hole assembly is a method of producing printed circuit boards in which the PCB has holes and leads are soldered through those holes. The result is a stronger, more dynamic board. It can handle a greater volume of parts and heavier components, as well as higher currents and voltage levels. Components on THT PCB assemblies are also much easier to rework, repair, or remove over time because doing so does not require specialized tools.

    To decide if THT is right for your PCB assembly, consider these specific factors:

    • Holes and Leads: The PCB first has holes bored into it. Then, manufacturers insert leads through the holes and solder them to pads.
    • Manual or Automated: Automated machines can insert and solder the leads into place, or the process can be done manually.
    • Size of Components: THT components are larger to accommodate the insertion technique and placement through the PCB.
    • Components Used: THT constructions typically feature capacitors, inductors, integrated circuits (ICs), and resistors.

    Typical applications of through-hole assembly PCBs include the following:

    • Aerospace: Aerospace assemblies rely on THT-style PCBs because the connections are less likely to fail.
    • Automotive: Because THT PCBs are reliable and robust, manufacturers often prefer them for control modules in automotive applications.
    • Industrial Electronics: Manufacturers use THT construction for industrial motor controllers, power supplies, and sensors.

    Surface Mount Technology (SMT)

    Surface mount technology (SMT) PCBs feature smaller, high-density components attached to the surface of the PCB. The parts are miniaturized to facilitate more compact designs on the limited surface area. This style of production is cost-effective, as the boards are smaller and don’t require as many drilling processes. Surface mount assembly PCBs also save time and money to assemble, as the entire process can be automated to reduce labor costs.

    Here are the main features to consider with SMT PCB assemblies:

    • Automation: SMT processes are relatively simple but require a high degree of accuracy, which automation can easily provide.
    • Size of Components: SMT components are smaller and lighter than THT components.
    • Components Used: SMT PCBs have miniaturized microcontrollers, capacitors, ICs, and resistors.
    • Direct Soldering: Parts are applied to the PCB via direct soldering, a process that can be automated.

    Due to the direct contact between the components and the PCB itself, SMT boards tend to have better heat dissipation. However, they must be properly designed to ensure effective thermal performance. Some of the common applications of SMT PCBs are:

    • Consumer Electronics: Small consumer electronics, such as tablets, wearable tech, and smartphones, benefit most from SMT design.
    • Miniaturization: SMT PCBs benefit projects that have compact form factors, such as medical devices.
    • Telecommunications: These PCBs are ideal for telecommunication devices and assemblies.

    Tips for PCB Design

    When you’re choosing between THT and SMT processes for the manufacturability of your PCB assembly, consider these five elements:

    • Clearance and Tolerances: Each component requires enough clearance for accurate initial placement and proper function during use.
    • Thermal Dissipation: In addition to integrating the proper space between components, you should also address any other potential thermal management issues with the board.
    • Component Placement: Your design should allow for the best possible component placement to facilitate efficient assembly processes.
    • Design for Testability: Designs also need to accommodate testing during production so errors can be caught as early as possible. Build in test points.
    • Pad Design: Different industries set different requirements for pad sizes and shapes, which may affect what manufacturing method is best.

    Through-Hole Assembly and Surface Mount Assembly PCBs From Circuit Pak

    Both THT and SMT assembly processes offer significant advantages, but each one works best for specific industries and use cases. Consider your project parameters, budget, expected product use case, and environmental factors to determine which one is best. Reach out to the experts at Circuit Pak to discuss both methods in more detail, or request a quote to get started.