How to Choose PCB And PCBA Assembly Service?

Choosing the right printed circuit board (PCB) assembly partner to collaborate with on the production of your PCBs is a key component in the success of your project. However, before you can select a proper partner, it is important to understand what goes into PCB assembly in the first place.

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PCB assembly is the critical stage in electronics manufacturing, where a blank PCB is populated with electronic components to create a functional circuit. This process usually involves two main techniques: surface-mount technology (SMT) and through-hole technology (THT).

SMT is the more commonly used method and involves the components being mounted directly onto the surface of the PCB. This enables the creation of smaller, lighter boards with higher connection densities and is generally faster and more cost-effective. 

On the other hand, THT involves inserting component leads through holes in the PCB and soldering them on the opposite side. This is more time-consuming and expensive, but provides a stronger mechanical bond for components to endure more intense conditions.

While SMT is preferred due to its efficiency and compactness, THT may be more appropriate if your product needs to withstand substantial mechanical or environmental stress or includes larger components like connectors and transformers.

Key Factors of a PCB Assembly Partner

To achieve optimal results with your next PCB manufacturing project, partnering with a reliable PCB assembly partner is crucial. Collaborating with such a partner will enhance the many steps involved in this process in several ways. 

When selecting a PCB assembly partner, it is critical to focus on quality and reliability, as these aspects are of utmost importance. It is worth examining the following key factors when deciding on a PCB assembly partner to ensure that the provider meets high standards in these areas:

1. Process controls and quality framework

Top-tier PCB manufacturers adopt stringent management systems to govern their assembly processes, often employing automation and advanced AI-powered Statistical Process Control (SPC) data analytics to maintain continuous visibility and control over critical process parameters. 

Such an approach helps in real-time monitoring, anomaly detection, and ensuring traceability throughout the production cycle. Understanding the specific process control methods, such as automatic feedback loops and error-correction mechanisms, allows you to assess how the manufacturer manages quality and consistency, which is crucial for ensuring reliable end products.

2. Inspection and testing capabilities

Comprehensive inspection and testing capabilities are essential for verifying the quality of PCBs throughout and following the assembly process. Leading PCB manufacturers integrate various testing methods into their processes, including In-Circuit Testing (ICT), flying probe testing, Automated Optical Inspection (AOI), and X-ray inspection, to ensure thorough quality assurance.

Each of these testing methods serves a unique purpose. ICT checks for electrical performance and solder joint integrity. Flying probe testing verifies component placement and connectivity. AOI locates visible defects, and X-ray inspection is good for evaluating internal structures and solder joints that are externally visible.

Assessing the application and effectiveness of the testing processes that a given manufacturer utilizes will allow you to confirm their commitment to delivering defect-free PCBs.

3. Technical experience and expertise

The technical experience and expertise of a PCB assembly partner also play a major role in providing reliable solutions.

Thus, it is crucial to evaluate their history within the industry, including the number of years they have been in operation, their staff’s engineering competencies, and their adoption of industry best practices. A manufacturer with a proven track record and deep technical knowledge is much more likely to effectively handle complex assembly challenges. 

You may want to specifically ask potential partners about the sizes of the batches they typically work with, the kinds of projects they have assembled, the components involved in them, and the industries they have worked with.

In addition, firms that actively pursue innovation in addressing technical issues and continually improve their PCB assembly processes are generally more reliable. 

Such technical acumen is usually indicative of their capability to adapt and provide high-quality solutions tailored to your specific needs, no matter what your demands may be. 

Another way to determine the expertise of a potential PCB assembly partner is to inquire about their quality certifications, such as ISO , ISO , or ASD. Possessing such certificates often indicates an adherence to high standards and consistent quality management.

4. Customer support

Although a prospective PCB assembly partner’s technical capabilities are important, it is also necessary to know what their customer support looks like. You should ultimately strive to work with a partner who will always do whatever it takes to find optimal solutions, answer your questions quickly, and help you fix any problems.

In most cases, you can get a sense of what a company’s customer service is like simply by engaging in some interactions with their representatives. The speed at which they get back to you and how helpful, polite, and knowledgeable they are will speak volumes.

You may want to ask the customer service reps you interact with about the services they offer, how flexible these services are, and whether they will work with you to customize your assembly and testing routine.

After speaking to the customer service reps, if you are still interested in learning more, check their reviews and testimonials online to get a sense of how other customers feel about their service quality.

Why Circuits Central Is the Perfect PCB Assembly Partner for You

If you are looking for a PCB assembly partner who can fulfill all the critical necessities mentioned above, look no further than Circuits Central. We have the knowledge, skill, and experience to handle even the most complex PCB assembly process thanks to our state-of-the-art production facility, top-notch equipment, and 25-plus years in the industry.

When it comes to technical expertise within PCB design and manufacturing, no one comes close to our seasoned experts, as we produce top-quality, high-performing PCBs of varying complexity for clients in different industries. Our track record speaks for itself, and we would be happy to help you achieve similarly successful outcomes as all of our past and ongoing customers. 

Not only do we offer a full spectrum of PCB manufacturing services, including PCB layout and design, PCB prototyping, PCB assembly, PCB testing, and upgrades, but we also have the flexibility to modify our approach to meet the specific needs of your company.

We also offer extensive customer support and will work closely with you every step of the way to ensure that your requirements are met to a tee. You will be impressed with how quickly and efficiently we manage our PCB manufacturing presses without compromising the quality of our end products. 

Turnkey PCB manufacturing services include design review, fabricating bare boards, procuring components, assembly, and testing of your prototype. Choosing a one-stop solution for all your prototype requirements can save you time and money.

In this article, we will show you the benefits of opting PCB manufacturing and assembly from a single manufacturer.

What is turnkey PCB manufacturing?

Outsourcing fabrication and assembly services to multiple manufacturers requires you to be involved in procuring materials and managing both stages. A faster alternative is to have your entire board built and packed by a single electronic manufacturer utilizing turnkey PCBA manufacturing services. This is because many of the fabrication and assembly stages are automated and parallelized with standard SOPs. This integration maximizes the progression of your boards from the initial quote with DFM/DFA review through shipping. Thus a one-stop solution for your PCB manufacturing and assembly requirements can work in your favor.

For more PCB And PCBA Assembly Serviceinformation, please contact us. We will provide professional answers.

Turnkey PCB manufacturing services involve:

• Fabrication solutions: Design review, sourcing dielectric materials, and bare-board manufacturing
• Assembly solutions: Sourcing parts, design assistance, board population, prototype testing, component obsolescence management, and aftermarket services

It is called ‘turnkey’ as PCBA arrives at your doorstep ready to be turned on and used, with all parts functioning as intended. All entities involved in this integrated process have access to design data whenever you need it. The figure above shows the important steps in board manufacturing processes and sub-processes.

Difference between PCB and PCBA

A PCB is a bare circuit board that is not yet functional. PCBA is a completed assembly with all the components attached to the board that will operate as desired for a given application. However, they are used interchangeably. PCBA services include bare board fabrication, sourcing parts, solder paste printing, component placement, and hand/reflow/wave soldering. PCBAs require anti-static or compartmental packaging whereas PCBs typically use vacuum packaging.

Benefits of opting for turnkey prototype services at the same fab house

Turnkey solutions allow you to make better use of your time to focus more on board design. It ensures that your design is tailored as per the CM’s capability. This is perfect for companies that frequently upgrade their products. Since they need to cater to a larger market by providing multiple creative electronic products, this calls for seamless fabrication and assembly processes.

Reduces prototype turnaround time

If you work with a single company, the production channels are limited. Potential incompatibilities in manufacturing equipment and software are also reduced. You need not stress over managing contracts and following up with multiple vendors as everything is included in a single purchase order. This results in a shorter production time.

Having multiple vendor pipelines adds to the delay. Shuffling your product between different facilities is a logistical nightmare that will cost you heavily and increase your lead time. There are chances of misplacing your parts in the process too. Having a single point of contact provides an opportunity for symbiosis and an effective PCBA development process.

The images below depict how having single or multiple vendors can affect the turnaround time of a standard 6-layer rigid board.

To learn the factors that can delay the lead time of your prototypes, see how to get a quickturn PCB in the USA.

Prevents miscommunication between vendors

Having many vendors will result in communication and compatibility issues, especially if there is a language and time zone barrier. This can slow down the prototype fabrication process. Turnkey PCB manufacturing and assembly approach allow for the whole process to be easily monitored as a single process. The sub-sectional supervision is handled by qualified experts within the manufacturer’s structures. A reputed board shop ensures good in-house communication between fabrication and assembly departments reducing manufacturing and population errors.

Gives more design improvement time

By choosing a single EMS company, you can use your resources/personnel and time for important design tasks rather than them spending time with follow-ups. Your CM will manage the entire process including component procurement, vendor(s) coordination, and quality control. Besides reducing project man-hours, you can dedicate more time to elevate your board design.

Provides efficient engineering design support

Design engineers use the best EDA tools available to capture and verify the schematics. This ensures that any design flaws in your board construction are eliminated in the initial phase, reducing the need for design modifications. A good CM will provide DFM and DFA assistance for your design. Their engineering team will be in constant communication between fabrication and assembly. This helps in catching errors quickly and results in producing reliable yet cost-sensitive prototypes.

Consider our PCB Design for Assembly Checklist: 9 Important Checks for Layout Engineers for a seamless assembly process.

Features:

• Identifies errors in your design ahead of time preventing on-holds and re-spins
• Provides an instant quote for your board
• Ensures that you have a complete set of design files required for manufacturing
• Optimizes soldermask and silkscreen data

Simplifies component sourcing process

Component shortage is one of the key challenges faced by many printed board assemblers. Finding reliable alternatives can also be tedious and time-consuming. This can be easily prevented by partnering with a company that offers turnkey PCB manufacturing services.

Component sourcing is a laborious process. There is also a likelihood of errors and compatibility problems. You may not even realize that the wrong part has been ordered until you assemble the prototype, delaying the process.

Sourcing reliable and good-quality components at bulk pricing will be easier through your turnkey manufacturer due to long-term cooperation with suppliers. They will have a large supply-chain contact base to meet all your board requirements. The fab house will have a team dedicated and a well-established system to ensure error-free assembly. They will manage your part needs with push (have buffer stocks) and pull (order only based on requirements) inventory strategy. In addition to this, the company will also manage customers’ consigned and customized components/materials.

A responsible EMS will also be proactive and provide early component sourcing. This prevents project derailment due to a volatile supply chain environment. It also mitigates the risk of extensive redesigns involving component alternatives.

Minimizes assembly defects

Sometimes, distributors can send mislabeled parts that don’t match the specs. Once the components are procured, the team verifies samples of each part to check if it is in line with the BOM specifications to prevent errors and delays.

Sierra Circuits follows a zero-defect initiative when it comes to assembly. We perform BOM cleaning early in the development stage to ensure that your boards can be produced at the intended scale. See how we successfully assembled a board by rectifying the design data in the case study, eliminating BOM and footprint errors in PCB assembly.

Design for Assembly Handbook

6 Chapters - 50 Pages - 70 Minute Read

What's Inside:

• Recommended layout for components
• Common PCB assembly defects
• Factors that impact the cost of the PCB assembly, including:
  • Component packages
  • Board assembly volumes

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Increases cost savings

Piecemeal-style manufacturing of PCB assemblies will lead to higher production costs. By choosing a single vendor, you save on the overall project costs like:

• Freight charges
• Component costs
• Customs fees
• Equipment costs
• Testing and certification charges
• Assembly
• Nonrecurring engineering (NRE) costs (includes pick place programs, stencils, reflow, and test fixtures)
• Costs due to extra resources costs

Costs are also optimized with shorter manufacturing times by following required SOPs.  At Sierra circuits, we waive charges for tooling, setup, stencil, and CAM reviews.

Negotiate the quote and relax until the PCBs arrive at your doorstep within the deadline.

For more assembly cost-saving strategies, read how to reduce PCB assembly cost.

Assures quality control

Board manufacturing and assembly, especially multilayered boards is a very intricate and expensive process. Any small mistake during these tasks can render the entire board useless. Hence, maintaining stringent quality control is essential in producing a high-performance prototype. A reputed turnkey PCB manufacturing and assembly service provider will implement many proactive steps to review the quality of their processes and circuit boards. Early DFM checks are a step towards guaranteeing quality. Their quality control department will perform comprehensive inspections and testing before shipping. Automated X-ray inspection (AXI), automated optical inspection (AOI), electrical tests, and special certification tests are conducted at their facility. Therefore, you can be confident that your PCB has no defects and will function as expected. X-ray validation is carried out for all leadless device connections. Every board is scrutinized by AOI equipment to verify the correct placement and orientation of all components. You need to make sure your fabricator has the required certifications and registrations.

Design for Testing Handbook

7 Chapters - 28 Pages - 45 Minute Read

What's Inside:

• PCB testing strategies
• Guidelines to design and place a test point for FPT
• Directives to make your board ICT compatible
• Benefits and drawbacks of various testing methods
• Defects that you can identify through board testing

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How to choose your PCB fab and assembly shop?

Do not rush the process of finding a good electronic CM. Your project should go from an idea to a finished product smoothly and consistently. It is essential to balance quality and cost to attain a successful prototype. Partner with a certified CM having a workforce who can provide a standard product using the latest technologies within the stipulated time. The criteria to choose the right EMS service provider are:

• Very good experience in a wide variety of PCB manufacturing and assembly services
• Responsive communication practices and support
• Adherence with industry standards like IPC and UL
• Utilization of advanced PCB technologies. Visit the contractor’s facility in person to check out their advanced machinery and capacity. Discuss the critical basics with them like project goals, high-level needs, and IPC class requirements.
• Established associations with material and component vendors
• Outstanding in-house design, testing, and inspection facility
• Allows easy prototyping with short lead times for PCB assembly
• Trusted IP protection practices to secure data
• Provision for online quotes, and orders

Why Sierra Circuits should be your preferred fab and assembly partner?

• We provide PCB development optimization for complex critical system requirements for diverse industries such as military, medical, aerospace, automotive, and industrial electronics.
• Sierra Circuits’ engineers and turnkey PCB manufacturing teams are always accessible and responsive from quote through production and shipping. You will be provided with timely and personalized services.
• Capable of delivering high-quality quickturn boards so that you have a competitive edge in the market. We do not have minimum quantity requirements.
• Equipped with state-of-the-art machinery to provide you with end-to-end PCB prototype solutions. Have a look at our production facility in Silicon Valley.
• Customer-friendly easy-to-use online quote process. Turnkey PRO quoting process provides fast and efficient pricing with no hidden costs.
• We possess the necessary industry standards. To know more, visit our certifications and registrations page.

Advanced machineries at Sierra Circuits

A few of the advanced machinery we use are:

1. 1. Dage 3D X-ray machines that incorporate rotating cameras. It allows us to view solder joints at individual BGA pins at various angles.
   2. Advanced Juki machines for assembly. This equipment can place up to components per hour all the way down to SMT component size. One of the reasons our turnaround is unmatched is because of the modular formats in the Juki machines. It allows us to prepare for pending jobs offline during an ongoing job.
   3. Camtek AOI machines have advanced optics and data processing algorithms to identify defects. They provide automated inspection solutions for advanced PCB and IC substrate applications.
   4. Schmoll and Pluritec depth control drilling machines are used for precision drilling, micro-drilling, and routing for quickturn and high-end applications.
   5. Orbotech laser direct imaging (LDI) equipment for patterning enables optimized PCB manufacturing to achieve the best imaging results at high speeds.
   6. ATG’s (Luther & Maelzer) FPT equipment is used for bare board examinations while Seica’s cutting-edge machines are used for final FPT evaluations post-assembly.

Apart from our excellent design and manufacturing capacity, we provide exceptional engineering, procurement, and customer services. We provide total visibility through every step of board development to see that your PCB is built quickly, efficiently, cost-effectively, and of the highest quality. We always look forward to building long-lasting relationships with our clients. Our electronic manufacturing services (EMS) guarantee a cost-effective and hassle-free quickturn delivery of your printed boards.

Before moving to mass production of your board design, read advantages of ordering PCB prototype and bulk production from a single fab house.

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