The PCB assembly process is critical to get right the first time. A single misstep here could result in malfunctions, lack of functionality, or even the threat of accidents. In this post, we’ll cover some of the most important PCB assembly process steps and what you should know.

It’s Not Board Manufacturing

First and foremost, understand that the PCB assembly process takes place during a specific time in the development of an electronic device. It’s not about manufacturing – that happens first. For instance, at Advanced Circuits, we’ll manufacture the board itself, including all the required layers, creating the traces, and all the other important steps, and then work on PCB assembly.

In short, PCB assembly is the process of bringing everything together into one place and creating something functional out of multiple components. It’s taking that newly manufactured board, adding components and resistors, and then making sure it does what it is intended to do.

Understand the PCB Assembly Technologies

Assembling a printed circuit board requires more than just the raw components and a well-designed board. It also requires the right technology. In this case, there are several options to choose from, and each brings something different to the table. For instance, there’s surface mount technology (SMT), as well as manual soldering, and the use of pick and place machines.

While some PCB assembly processes will require just one technology, others will require a combination of two or more technologies. For example, many boards require the combination of through-hole technology (THT) and surface mount technology. Understanding when, where, and how to integrate those technologies is a critical consideration when choosing a company to handle your project or production.

It’s also important to understand that the PCB assembly steps involved with the various technologies differ, as well. Below, we’ve outlined some basic steps involved, as well as how they differ from technology to technology.

The PCB Assembly Process: An Overview

• Solder Paste: If you’re following a traditional PCB assembly process, the first step is the application of solder paste. Note that this is not the case with THT, but SMT does require paste application and/or printing.

• Component Placement: In the traditional PCB assembly process, the next step is to place the components on the board. This can be done manually, or it can be done with the assistance of machinery (pick and place systems). In THT assembly, components are placed by hand, which requires incredible precision. In the SMT process, robotic systems place components on the board. Note that automated placement is far faster than manual placement and is just as precise.

• Reflow: In the traditional PCB assembly process, the next step is reflow, which is when the solder is first melted and then resolidified. The board and all its components move through an oven, which heats the solder, liquifying it and ensuring that connections are formed before the board moves into a cooler, where the solder is cooled.

Note that the THT process does not require reflowing solder. Instead, the second step here is to inspect the board and rectify component placement. This is due to the manual placement process – a visual inspection in conjunction with a design transport frame helps ensure placement accuracy.

In the SMT process, reflow soldering takes place at this time, as well. The board is sent through a furnace, which melts the solder paste, allowing it to flow as necessary, before the board passes through a series of coolers that gradually bring the temperature down, solidifying the solder on the board and cementing the components in place.

• Inspection: The next step in the traditional PCB assembly process is a visual inspection of the board, soldering, and components. Note that this step has already occurred in the THT and SMT processes.

• Through-Hole Part Insertion: The traditional process requires that through-hole insertion be done manually, after the reflow and inspection process. Soldering is also often done manually, but it may be done using wave soldering.

Wave soldering occurs during the THT process at this point, as well. The entire board moves over liquid solder and then moves through coolers to solidify the solder.

Note that there is no correlating step in the SMT process (it is actually already finished, and wrapped up after just three steps, although a visual inspection should still be conducted to ensure accuracy and to reduce the potential for errors).

• Final Inspection and Cleaning: The final step in the traditional PCB assembly process is a final inspection of the board, the solder points, and the components, and a cleaning to ensure that debris or excess solder is removed.

The Right PCB Assembly Process for You

While the SMT assembly process is faster and often more accurate than either the traditional PCB assembly process or the THT process, it is not always the best option. For instance, if you only need a single prototype board assembled, the THT method might be the better choice. Each situation varies and there is no single solution that will always work for every need.

At Advanced Circuits, we understand that needs, budgets, and goals vary. We pride ourselves on offering exactly the solutions each client needs. Whether you’re producing a single prototype for proof of concept needs or you’re ready to move into full production with thousands of units being produced, we can help. Contact us today to schedule your consultation or to learn more about our services and capabilities.

Know Your Goals with the Printed Circuit Board

Before you start to design the PCB and long before it can go through the circuit board assembly process, you need to be sure that you know what the board needs to accomplish. Different types of boards may have different functions. Some might be relatively simple, while others may need to handle more functions. Those who have complex needs from their boards will likely need to use multilayer PCBs. This will allow for more functionality in less space.

Take the time to determine what the goals are for the board before beginning the design. Designers will find that having a solid plan in place even before heading to the software will help to keep them on the right track.

Sometimes, the design that you create will not work as intended. It’s always better to find this out in the early planning and designing phase rather than when the boards are being printed. Take the time needed to perfect the design. A good plan and the right software will help with this.

Use Quality Software

When designing the boards, you will want to be sure that you are using quality software that is made specifically for PCBs. Good software can help to make the process of designing easier, and some programs will even offer the ability to check the files before they move to the circuit board assembly process. They can find errors, and some software can fix certain errors to make your work easier.

If there are potential problems with the design, you can go back into the software and make the needed adjustments before you move to the process of circuit board assembly. This helps you save time since you won’t have ordered a prototype that doesn’t work and then try to figure out why. Once you are certain that your board is in good shape, you can then get a prototype or have a large number of the boards manufactured.

Generally, you will want to have prototypes done first. Order just a single board, or a few, and test them out. See how they work, how they stand up to different situations, etc. This will let you know if you need to do any further design work before moving into the manufacture and circuit board assembly phase.

Of course, many will worry that prototypes will be difficult to get because some manufacturers do not want small orders. When you work with Advanced Circuits, you will not have to worry about this since there are no minimum orders. We also provide an engineering check to ensure it will work, and you can use our free software to design the boards.

Hire a Professional for Manufacturing and Assembly

After you are certain that you have a circuit board with a good and usable design, it is time to assemble the boards. However, you may not want to attempt this on your own. Consider just how much time and space it will take to perform circuit board assembly, even for a few hundred boards. If you have thousands, it will be next to impossible for you to do on your own unless you already have a facility dedicated to production.

This is not the case with most designers, so it makes more sense from a logistical and financial perspective to work with professionals like Advanced Circuits. If you were to try to set up an assembly facility of your own, you would need to have additional space and likely additional employees. Also, there would not be a guarantee that the circuits were working properly.

You need to have a manufacturer that has the space, expertise, and tools available to manufacture the circuit boards. Outsourcing the circuit board assembly is typically the best option. Of course, you can’t entrust your boards to just any manufacturer.

Why You Should Work with Advanced Circuits

You now have a better understanding of why you will want to work with professionals and why you need to have a quality design to start. It is time that you connected with Advanced Circuits. Our company is the third-largest printed circuit board manufacturer in the United States.

On our site, you can download our free software for designing your printed circuit boards. This helps to make the process of designing faster and easier. This is not just some simple software, either. You will find that it is a professional-grade software that has more features than many paid programs. It is easy to use and it includes a free online file check that lets you look for any manufacturing issues that might be present before going into production.

Advanced Circuits is known for being reliable and providing quality PCB fabrication. Additionally, we are financially stable, which means you will not have to worry about the company going out of business.

We are known for using quality materials, providing reliable PCBs, and having a fast turnaround time. Our experience helps to ensure that the boards are made and assembled correctly and that they reach you quickly. We also have around-the-clock tech support, so you can always talk to an actual human when needed.

If you need professional printed circuit board assembly, it is time that you got in touch with us. We have the means and the expertise to help you get what you need quickly and easily. Check out the software, get a quote, and get your boards faster than you might believe.

High-Quality Materials and Assembly

When working with a professional company for printed circuit board assembly, they will typically be using the best possible materials and assembly tools for the job. While this may not be true of all companies offering these services, the reputable companies that have been around for a while will. Choosing a company that can offer the best materials and that provides topnotch assembly services helps to ensure that the final product is perfect.

Naturally, you want to be sure that the circuit boards you are using are the best quality they can be before you start to use them or sell them. Choosing professionals rather than trying to assemble them on your own, in-house, will help to ensure this.

Find Errors Early

Even those who have been designing printed circuit boards for years can make mistakes during their design. A mistake that is followed for all of the circuit boards that are constructed would mean a huge error that could cost your company a lot of money. Rather than letting this happen, you could be working with a professional for the printed circuit board assembly.

At Advanced Circuits, for example, we have engineers test the design – even after you have tested it – just to be sure that there are no issues that could crop up down the line. This provides you with the peace of mind you need to go ahead with the full assembly. You will know that the boards will work properly once they have been assembled.

The software that is available through our company is free, and it can do more than just help you design a circuit. It helps to make it easier and reduces the risk of errors. When the boards are submitted, we will check to ensure that they have been designed correctly. The earlier the errors are detected, the better. It means that you can fix those problems before you go into full manufacturing mode.

Save Time

Consider how much time you would be spending if you had to manufacture and assemble all of the PCBs at your own facility. You would need to hire extra people just to keep up with the manufacturing and assembly needs. It would take up a lot of time that could better be spent working on other aspects of your company. It makes far more sense to hire professionals for the printed circuit board assembly. They can take care of the assembly, whether you need one PCB or you are in the market for thousands of boards.

Reduced Manufacturing Costs

Additionally, consider the manufacturing costs that you would have to incur if you assembled the boards on your own. You would need to have a large space available for the printed circuit board assembly. You would have buy all of the materials and tools needed, and more. You would likely be spending far more money than if you had just hired a professional company to take care of the assembly of the boards for you.

You can talk with companies like Advanced Circuits to get an estimate of how much it will cost for the PCBs that are needed. When you compare this with the cost of increasing the size of your facility and hiring more people for the printed circuit board assembly, you will see why outsourcing is such a good idea.

Turnaround Time Can Be Fast

One of the reasons that some companies still consider in-house printed circuit board assembly is because they worry that another company won’t be able to help them meet their deadlines. This is not necessarily true. When you choose a company that is known for having a fast turnaround time, you can get the boards in a matter of days in many cases. Of course, it will depend on just how many of the PCBs are needed and the company you choose for assembly.

Shipped Directly to You

Once the printed circuit board assembly has been completed, the manufacturer can have them shipped right to your door. The shipping time can vary, but when you choose a quality manufacturer like Advanced Circuits, it tends to be fast. This means you will be getting the circuit boards you need quickly.

Choose Advanced Circuits for PCB Needs

Naturally, you will want to be sure that you are choosing only the best for your printed circuit board assembly. You should take the time to consider just what the company offers, along with how fast they will be able to provide you with the completed boards. Price, of course, is another factor. You want to choose a good company that remains affordable and that can provide quality customer service.

Now that you know more about the benefits that are associated with using a professional for printed circuit board assembly, it’s time to find a company that can provide you with what you need. At Advanced Circuits, we strive to provide our customers with the best service and products from start to finish.

Whether you simply need a prototype, you have a short run that you need, or you are looking for a substantial number of boards, we can help. Get in touch with us today.

Why should turnkey PCB assembly be a challenge? There are many steps involved. Just consider a few of them:

• Initial design
• Output to design for manufacturing or DFM checks
• Film creation
• Mapping of copper paths
• V-scoring
• Testing, and all of the phases between and after

Not surprisingly, any firm that offers same-day turnarounds for turnkey PCB assembly seems like an impossible thing, but at Advanced Circuits, we offer just that, and more.

A One-Stop Turnkey PCB Assembly, Design and Shipping Shop

We offer more than 25 years in the circuit boards industry and rank among the largest of the one-stop solutions for manufacturers in need of prototypes, stencils, supplies, and turnkey PCB assembly. We operate within a facility that includes tens of thousands of square feet of production space and offer clients a turnkey PCB assembly system that includes everything from design testing and submission to packing and shipping.

We offer clients such vital services and options as:

• One day PCB – We are one of the few PCB makers that can manufacture and assemble circuit boards and ship them out in as little as a single day.
• Full support – Unlike many other manufacturers, our team works with orders of any size, every step of the way. We begin with a quote based on initial design uploads, and take a project to final production and turnkey PCB assembly phases.
• Quality – Our design process is not of the “no-touch” variety where the designs are sent in and run into production right away. Every single order (whether one-off or thousands of PCBs) gets our full CAM review, as well as visual inspections of the final circuit boards produced.
• Transparent pricing – Also unlike many other producers, we do not ask for stenciling fees, setup fees, and other hidden, but ultimately unnecessary, charges on turnkey PCB assembly projects.

We are truly a one-stop system, ensuring a seamless process under one roof. Clients’ orders or projects remain in the hands of our engineers from beginning to end, and even before, as we have 24-hour service offered by authentic CAM engineers who take questions at all hours. Without any outside vendors (we are not a broker) and with production and full turnkey PCB assembly in a single space, there are almost no risks of delays, problems, and mistakes.

What We Include in Turnkey PCB Assembly

The speed and ease offered by a turnkey PCB assembly team are invaluable, but we also make some incredibly handy resources available too.

• PCB Artist Software – The cost of PCB design software is part of doing business, and it can be a huge expense. Advanced Circuits’ clients enjoy free use of our proprietary design software (an industry best) in an unrestricted format and entirely for free. It downloads to the desktop (Windows only at this time) and offers up to 28 layers in a single design. The program has over 500k parts from which to choose, integrates a controlled auto-router function to speed up design processes, and offers multi-page schematics for more complex projects. With a complete library of tutorials to train those using the program, there is almost no learning curve and even if errors are made, there are steps to the turnkey PCB assembly process that catch mistakes before
• Ordering through the software – When a client runs the proprietary software available through the site, we also provide them with a discount for ordering through it at the same time. Designs still get a CAM engineer review and crucial checks for errors, too.
• FreeDFM – For those already using a CAM program, turnkey PCB assembly is still supported by this design testing option. Files are imported as Gerber files (industry standard) and then loaded to the online software. This will review the entire file, correct any problems, and generate a report indicating changes or potential problems.
• No minimum orders – Whether a client needs a prototype or a large run, there’s no worry about minimums, ever.
• CAM Engineer Evaluations – All products are evaluated by one of our in-house engineers long before production begins, to spare clients any costly mistakes.
• Customers get authentic tech support – We go beyond basic customer support and offer turnkey PCB assembly clients the opportunity to troubleshoot with the help of a CAM engineer available 24 hours a day.
• Premier shipping – Any turnkey PCB assembly orders come with the BEST ON-TIME SHIPPING in the industry, and we are now shipping 50% of orders early! In fact, we ship Standard Spec orders on time or they’re FREE!

No Outsourcing with Advanced Circuits: We Proudly Produce & Stand Behind Our Work

It is a frustrating truth that most manufacturers face the risk of outsourcing on almost anything they use or buy. Outsourcing is no longer limited to customer service and other phone service options alone, and if it is turnkey PCB assembly that is in question, the risks of trouble increase with outsourcing. From errors or flaws in the design process, to manufacturing glitches that result in wasted money and time, it is unwise to look to brokered or outsourced solutions for a turnkey PCB assembly process.

Working with Advanced Circuits means buyers get the kinds of hands-on results that are so important and desirable. With us, all circuit board designs pass through a series of rigorous examinations long before production begins. We are not a broker but are instead a reliable one-stop solution; making everything in-house, eliminating production problems and supplying turnkey PCB assembly and results required for success.

After all, prototyping means designing something new, having the unit made, addressing flaws or design issues, and only then sending it into production. There is always the risk that a design flaw might be overlooked, and working with subcontractors can actually increase such concerns. All of these factors are why so many people will avoid the entire process and stick with a less than desirable solution. Settling for a stock or standardized design, however, is not a forward-thinking approach.

The good news is that there is no such thing as one size fits all circuit board design. Advanced Circuits, a top industry manufacturer, offers an array of resources capable of empowering firms with even limited budgets to upgrade, customize and enjoy flexibility. Of course, it helps to have a bit more clarity on just what is available generally before delving into the options in custom printed circuit board design.

The General Options in PCB Design

A simple or basic list of the options for PCB design include:

• Single Layer
• Double Layer
• Multi-Layer
• Rigid
• Flexible
• Flex-Rigid
• High-frequency
• Aluminum-Backed
• Full Spec
• LDI
• Oversized
• Heavy copper
• and more

Clearly, this means an array of production capabilities has to exist and come in at the right price and quality points to meet such a diversity of potential needs or designs. Advanced Circuits can supply almost any type of production capability and facilitate premium circuit board design that goes along with it.

Optimal Circuit Board Design from Advanced Circuits

In addition to there being such a diversity of PCB types, there will be many design needs. For example, printed circuit board design may involve only a single layer, or it might be two-sided, but the complexity of modern electronics may necessitate up to 28 layers incorporated into a design, and each layer will require synchronous interaction. This means there is always room for error in circuit board design, and the option for multiple sets of eyes and various levels of expertise may prove remarkably beneficial and cost effective.

Because of that, Advanced Circuits has created a system of tools, resources and services that are all meant to facilitate optimal circuit board design. The resources and services include:

• Expert advice – In addition to classic customer support, our team includes access to CAM engineers 24-hours each day. Customers are able to phone in design and engineering questions and have them answered by a professional engineer.
• Expert Reviews – CAM engineers also conduct a thorough review of each design as it is about to enter into the production process. This is a final check and guarantees that there are no issues that might lead to a negative outcome.
• Full and free design support – In addition to expert engineers, Advanced Circuits offers industry best software meant to enable superior design. PCB Layout Software – PCB Artist features a library of more than 500k tools and components that can be built into designs of up to 28 layers. It can control auto router functions, multi-page schematics, and more. It is offered in an unrestricted format, meaning it comes at no cost but allows top-of-the-line design options.

After that, clients are able to use the FreeDFM program, which requires an export to Gerber file format and upload to the Advanced Circuits website. Once that fast and easy process has been completed, the client can enjoy a full evaluation of the PCB design. A report is emailed to the provided contact and it explains which flaws were discovered, remedied and what were targeted as potential showstoppers, but left in place.

As any professional knows, PCB design is the key factor in the whole process. A single error makes a prototype a failure or an entire batch of PCBs useless. It could lead to enormous wastes of time and resources. Yet, the entirety of the process does not begin and end with design. There are other factors that impact whether or not printed circuit board design is as successful or effective as it could be.

A lot of it has to do with the approach the producer takes to the process. Advanced Circuits ensures that its clients experience a process that empowers their success, from the design phase to assembly. This means that we:

• Keep it in house – Our enormous production facilities are Advanced Circuits’ way of proving commitment to the entire process. We are able to work with design files and a team of engineers that ensure files are complete and appropriate to the client’s goals. However, we also handle fabrication and assembly on the premises, too. While so many modern manufacturers are “no touch,” we are most distinctly hands-on and manage every aspect of a project.
• Comprehensive website – The ease with which clients can get the tools needed and then use them effectively is only one part of our service. We also provide instant quotes, unique client pages where previous orders and simple reorders are possible, stencils, file uploading, order tracking, and “through software” orders. Design something using the free PCB Artist software, and order it once it has cleared the CAM or free evaluation services. This also gives clients a discount on any standard spec orders.
• Tooling fees – Many manufacturers impose a tooling fee on standard spec orders, but clients can count on a fee-free process with Advanced Circuits. Even if a custom spec orders is re-ordered, the tooling fees are cancelled out.
• No minimum orders – Budgets are protected by Advanced Circuits’ no minimum order requirements, and whether it is a single board with a single day of turnaround time or a huge order, the quantity is in the hands of the clients.

Advanced Circuits Removes the Challenges in the PCB Production Process

The PCB design and production process is full of potential challenges and issues. Advanced Circuits clients receive their specific designs without breaking the budget, slowing production times or wasting resources. Whether clients need one PCB, small batches or larger orders, Advanced Circuits can produce quality printed circuit boards to client requirements.

To get an instant PCB quote and learn more about our quick turn capabilities, review our standard and custom spec PCB page.