pcb assembly

PCB assembly is a very precise and highly-technical process. In order to ensure the finished product meets every specification exactly, manufacturers rely on a number of documents provided by the client.  Although manufacturers work with documentation frequently, clients (especially new clients) may require some guidance in order to understand what information to provide and when. In this overview of documentation for PCB Assembly, we list the documentation required by most manufacturers and outline the benefits of a complete documentation package.

The Importance of Documentation

A PCB Assembly project requires countless specifications. Manufacturers make quality PCBs, of course, but even the best board is useful only if it meets client requirements.The documentation packet protects both parties and causes the assembly to run as smoothly as possible. By providing written instructions, the client establishes what is expected of the finished product. The manufacturer follows the specifications precisely, ensuring the client receives exactly what they asked for. Documentation eliminates any guesswork or miscommunication that may have occurred during verbal agreements. 

Key Documents

While requirements may vary slightly between manufacturers, most documents are quite standard to the industry. These include:

• Gerber Files
• BOM in MS Excel File
• Test specifications
• CAD Files in ODB++
• Assembly drawings
• Approved vendor list

Obtain a quote using complete documentation. Doing so will guarantee the price and timeline are accurate. More importantly, the manufacturer will have to input the specifications only once, which dramatically decreases the risk of human error. 

Regardless of project size, every PCB Assembly ought to meet several requirements which are specific to each client and each project. Because accuracy is paramount, detailed, precise instructions are a common requirement in the PCB Assembly process. Consider the document types listed above when preparing for PCB Assembly RFQ and build.

BESTProto is a leader in PCB prototyping, PCB assembly, and PCB production. Contact us today for a quote on your project: 224-387-3283

Inspection is a crucial part of the PCB production and assembly process. The inspection process is to ensure high quality and reliable printed circuit boards are assembled. The inspection process helps reveal any design flaws that may exist at different stages during manufacturing and the assembly procedure that must be eliminated. 

This blog post will inspect the leading inspection methods. Here is an overview of the various PCB assembly inspection methods. 

1. Visual Inspection

Manual visual inspection is the simplest form of PCB inspection. This inspection method can be used after most PCB assembly processes have been conducted. To perform this type of test, a worker looks over the board either with the naked eye or through magnification. Although visual inspection is a method commonly used, its validity depends on the capability of the inspection staff and how they apply the inspection standards.

2. Structural Process Test Inspection Systems

Structural process test inspection is often used for large volumes of production where accuracy and speed are extremely important. This inspection method uses some form of light emissions such as visible lights, lasers, and x-rays to acquire data through real-time image processing for locating and measuring defects related to solder joint quality. 

3. Automated Optical Inspection (AOI)

This method typically conducts an inspection using multiple visible light sources with programmable LEDs, one or more still or video cameras and computerized systems for inspecting solder joints.

An automatic optical inspection can find many of the same defects that a VMI can, including open circuits, solder thinning, missing components, displaced components and more.

4. Component Value Verification

BESTProto uses the latest technology to verify that not only the correct package size and types are being placed on a board but, we are also able to electrically test the individual components before placement to verify that the are the correct electrical value as well.

5. X-Ray System Inspection 

The X-ray method can be performed in two different ways: the X-ray fluoroscopic system and the X-ray lamination system. The fluoroscopic system produces a density image to accurately inspect solder joint distribution, thickness, and internal integrity. The lamination system, on the other hand, uses X-rays to generate focal planes of a horizontal sectional area of a PCB. 

Inspection is a crucial part of the PCB production and assembly process. There are five different types of manufacturers, and assemblers can use to inspect the PC board assemblies and help to eliminate workmanship defects. BESTProto ensures quality through our quality assurance program and continues our commitment from first articles through a disciplined approach to process control. Contact our team today to request a quote on your PCB Assembly project today.

There are four crucial stages for creating and implementing printed circuit boards, including design, manufacturing, testing, and, of course, PCB assembly. Traditional processes do not always incorporate all independent stages from the start; neither do they require the input of the contract manufacturer from the onset. Over the years, this practice has led to unnecessary hold-ups due to modifications in fabrication and design that expand the time to market. When we look at the future impacts of PCB, a more effective PCB manufacturing process must be implemented.

The Need for Change

In 2014, the market for bare PCBs surpassed $60.2 billion. By 2024, the PCB market is expected to exceed $79 billion. The demand explosion in the electronic market augments the growth witnessed in demand for PCBs. Therefore, PCB manufacturing industries must seize the opportunity by boosting productivity which is only possible with a more effective PCB manufacturing. 

Factors Impacting the Effectiveness of Your PCB Manufacturing Process

Every PCB manufacturing process needs an objective. Usually, the aim is to transform the PCB design into a quality, assembled product that can be reliably used for its intended purpose. While different PCB projects have their own costs and deadlines, the practices you implement can significantly improve your processes:

1. Select the Right BOM Materials

Making available crucial materials on your BOM can augment the PCB manufacturing process and prevent long lead-time or shortages. Therefore, it is essential to create a comprehensive list of suppliers that can deliver genuine components.

2. Using DFM Guidelines

Every PCB product has specific regulatory standards that must be met. Therefore, it is essential to consult with the contract manufacturer’s DFM (Design For Manufacturability) guidelines at the start. This ensures that the PCB layout meets standard industry specifications and tolerances and avoids wasting time and money in designing.

3. Consulting for PCB Assembly

It is recommended to consult with your EMS (Electronic Manufacturing Services) supplier or, contract manufacturer (CM), which provides access to valuable insights on how to maximize assembly efficiency and reduce assembly costs. The design files should also be made available to the CM in the preferred format to avoid errors.

4. Testing

Collaborating with the CM during testing ensures that an objective and independent assessment is made on your prototypes. This way, you can effectively locate and deal with all types of faults.

The bottom line is that with strategic CM and PCB assembly partners, you can effectively improve all stages of production. Finding the right partners will help you control costs and leverage current trends without sacrificing quality. BESTProto offers electronic assembly services for single or multi-layer flexible or rigid circuit boards. Contact us today to request a quote for your PCB project.