cost saving SMT – Advanced Circuits | PCB Manufacturing & PCB Assembly https://www.4pcb.com/blog Printed Circuit Boards and PCB Assembly Manufacturer Blog Wed, 17 Nov 2021 21:57:53 +0000 en-US hourly 1 Benefits of Surface Mount Technology /blog/benefits-of-surface-mount-technology/ Thu, 14 Jan 2021 21:23:41 +0000 https://dev.4pcb.com/blog/?p=2355 Continue reading ]]> For decades, through-hole circuits were the industry standard. They were relatively simple and required holes in the board. The components were mounted on one side of the board, and the leads were threaded through matching holes. Anyone who has ever worked with a breadboard to design a simple circuit will have a good understanding of how these types of boards were created.

However, as the demand for electronic devices increased, there became a need to automate the process of manufacturing the boards. Unfortunately, it was soon found that using automation would be difficult. It was not easy to get the right components and leads matched up with the right holes. It ended up taking a long time and costing a lot of money. Therefore, surface mounted technology was created to make things easier from the design to the assembly.

Surface mount technology offers a host of advantages and benefits, and over the past several decades, it has become the standard for manufacturing PCBs. Let’s look at some of the biggest benefits that it can offer.

Smaller Size and Greater Design Flexibility

One of the most commonly cited benefits is that surface mount technology means it’s possible to create smaller PCB designs. This is because you can increase the component density on the board. More of the components can be placed in a smaller space but will still provide the capabilities and performance of a larger board.

This means that the devices that will eventually contain the printed circuit boards can be smaller, as well. Smaller electronic devices and smaller boards are always important. It often means that a device that is complex can fit in a person’s pocket, such as their smartphone. People tend to like going smaller with most types of technology.

This also means that the weight of the boards will be lower. The lower weight provides even more possibilities for designers. For example, having smaller and lighter boards placed in drones means they will weigh less and use less power to fly. Cutting the weight out of items could also reduce shipping costs in some cases. Lightweight tends to be better, and this is another area where SMT can excel.

Easier Assembly

Because there are not any through-holes to worry about with these boards, it tends to make them easier to assemble. Easier assembly for the manufacturer will generally mean faster assembly, as well. This means you get your boards more quickly. Typically, it also reduces the potential for mistakes during the assembly process.

Lower Cost

Because the assembly is easier and because the boards are smaller, it often means that the cost will be lower, too. Of course, the company you choose to do the manufacturing will also be a factor in how much it costs for the boards.

Does Surface Mount Technology Have Any Disadvantages?

With all of the benefits that SMT can offer, you might be wondering if there are any disadvantages. While most will agree that the benefits will outweigh the drawbacks, it’s important to note that there may be some disadvantages. For example, because there is only a small amount of lead space, it could make repairs more difficult. Additionally, if a component has a high electrical load or if it generates a lot of heat, it can’t be mounted using SMT. This is because the solder could melt under intense heat, which would end up rendering the PCB useless.

What’s Right for Your Needs?

What option will you be using to create your boards? Surface mount technology can work well for many different types of PCBs. However, there could be times when through-hole solutions, or some hybrid of the two, will be a better option.

Using software like PCB Artist is a good way to design a PCB and see whether it will work virtually. The software is easy to use and offers more than half a million components for design work. After designing your PCB using the software, the design can be reviewed to determine whether it will work or not. This way, you have a second set of eyes looking at the work to ensure it’s ready to go.

Get a Prototype

However, even with an engineering file review, it’s important to get hands-on time with the PCB using surface mount technology before going into full production. After you’re happy with your initial design, you will want to order a prototype. Getting just a few boards is easy when you go through Advanced Circuits, as we don’t have a minimum order.

When you get the prototype, you need to put it through its paces in real-world scenarios. What types of conditions will the board face when it’s used in your device? Monitor how it works and take note of any areas that may be having problems. Putting it through a rigorous testing process will help to make it easier to find any potential problems.

It’s always better to know about problems sooner rather than later. Just assuming that the design is good and ordering 5,000 PCBs that end up overheating would be a huge problem for your company. There is also the potential that it could reduce the trust your customers have in your products. Finding and correcting the design before it is mass-produced, even if it takes a couple of prototype and revision rounds, is a better solution. It will save money and keep your customers happier in the end.

Manufacturing

Once you are pleased with your design and you’ve seen how it will work in real-world situations, you can then move to the manufacturing stage. Advanced Circuits can do more than just provide software and guidance. We’re a full manufacturing facility that makes all of the PCBs ourselves. We also have a fantastic turnaround time, getting PCBs to our customers within a matter of days.

We have a substantial amount of experience with the assembly of surface mount technology boards and can provide you with exactly what you need. Get in touch for a quote and to learn more about the services and options that are available.

 

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The Many Benefits of SMT Technology: Stepping Up the Electronics Manufacturing Game /blog/the-many-benefits-of-smt-technology-stepping-up-the-electronics-manufacturing-game/ Tue, 22 Dec 2020 20:08:57 +0000 https://dev.4pcb.com/blog/?p=2337 Continue reading ]]> SMT technology is a slightly redundant term in that “SMT” already stands for surface-mount technology, but for the sake of explaining the method and process, some people refer to it this way. Regardless of what it’s called, it is the main assembly method used on printed circuit boards and it has several benefits for the producer and the end user, alike.

If you’ve been around our site at all or have been following our blog, you’re likely already familiar with some of the basic concepts of PCB manufacturing, including surface-mount technology and how it works. Here, we’re going to dig into the benefits of using this type of manufacturing and what it can do for your brand, as well as the value of working with a reputable, industry-leading brand like Advanced Circuits for all of your PCB prototyping and production needs.

A Quick Refresher

This technology was first developed back in the 1960s, and by the 1990s, almost all high-end PCB components used the surface-mount method of attaching components because it allowed for easier connections and more components on a single board than previous manufacturing and mounting methods. Surface mounting means there is no drilling required, as the components include caps or tabs that can be directly attached to the board.

As you can already see, there are several potential benefits to be found here. Not only is it a more efficient and better use of space, but it offers plenty of other perks.

Flexibility

The mounting of these boards is much more flexible than other types of technology. Since all the components are surface-mounted, there is no need for the through-hole drilling or pesky dual-sided components that could get in the way of how the boards are used or installed. Components can even be placed along both sides of the board at a denser rate, allowing for more connections in a single board for flexible manufacturing needs and designs. Boards can also be mounted in several different ways when this technology is used, allowing for better construction and builds.

Quality Control

Repetition is the key to quality control, and that’s why PCBs with surface mount technology continue to lead the way in terms of quality. The process is done the same, every single time, when SMT technology is used. This means that the results will be better and the quality will be higher. Before, it was an individual process that was much harder to control and quality was always uncertain, at best. Today, however, PCBs are some of the most reliable items in terms of quality when they employ the use of surface mount technology.

Replication

Again, being able to replicate a successful product is going to save a lot of time and hassle. This not only benefits quality control, but it helps streamline everything. Once a board has been created and mounted, it can be replicated time and time again, with the same methods, ensuring that there is more efficiency in production, less waste, and fewer errors along the way. It saves time, money, and manpower.

Smaller Designs

Because more components can be placed near each other on the boards, surface mounting allows for smaller PCB design in the first place. This means that boards, and their corresponding electronics, can be much more compact and portable than ever before. It’s the difference between a desktop computer and carrying a smartphone — being able to mount components is what makes microscopic chip and circuit design possible.

Reduced Expenses and Waste

As mentioned, when employing SMT technology, the amount of waste is reduced significantly. Being able to repeat a process effectively and create high-quality components is going to save on bad boards, errors, and more. Plus, you can test and get a prototype of a single PCB to ensure that everything is working and functioning in the best ways possible before you order thousands of boards for production. This reduces testing and production costs, reduces waste, and helps everyone become more efficient with their PCBs.

Quicker, Easier, and More Efficient

Even the process of SMT is much quicker to set up, saving on initial costs. There is no drilling required, which saves a huge step and expense in the production process. Plus, the boards can be made quickly because they are repeated time and again, with a single process that is streamlined for optimal efficiency. The components are also able to be selectively soldered, with customization for each component available as needed. It’s all about making technology better and making the production process more efficient is the first step.

Stability and Performance

Surface mount technology is also much more stable than drilled and otherwise attached components. SMT allows better mechanical performance and durability, even under high vibrations or shaking conditions. These printed boards are more compact but still feature high-end components, meaning they can also be packed in tighter for more security in any environment. These boards even have lower resistance and induction to reduce the RF signal effects and provide more reliable performance.

The List Goes On

There are so many different benefits to using surface mounting in today’s printed circuit boards. From the improved production process to better performance in application, there are plenty of perks that will keep companies capitalizing on this technology for as long as they can. That is, at least until something better comes along. Any company that is working with PCBs needs to consider the benefits of surface mounted technology if they’re not already using it. It’s leading the way in PCB manufacturing and it’s waiting to help anyone who needs it.

To learn more about the various advantages of SMT technology and what it can do for your circuit board printing needs, contact the team at Advanced Circuits. We’ve been working with PCBs and utilizing the latest technologies and solutions for years, giving you peace of mind that you’ll get the best results when you work with us. From prototyping to full production, we can do it all, so call us today.

 

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Surface Mount Technology in PCB Manufacturing Made Easier than Ever /blog/surface-mount-technology-in-pcb-manufacturing-made-easier-than-ever/ Fri, 17 Jan 2020 23:16:52 +0000 https://dev.4pcb.com/blog/?p=2097 Continue reading ]]> SMT, or surface mount technology, is essential for most of today’s printed circuit boards (PCBs). Almost every higher-end device enjoys the benefits of using surface mount technology, which include:

  • Offering many more capabilities – The weight of a PCB that uses surface-mount technology, instead of labor-intensive and error-prone drilling and soldering means that the capabilities are improved. The era of shrinking devices means that the capability to create PCBs smaller and lighter than ever is a major advantage.
  • Saving time and money – The time and complexity of drilling is eliminated when surface mounting can be used instead.
  • Using automation – It makes sense to leverage the ability to mass-produce PCBs that retain performance and quality, and surface mount technology is one sure-fire way to do so.

Not all manufacturers have the ability to offer their clients surface mount technology in their design, manufacturing and assembly processes. However, Advanced Circuits has made certain that buyers can utilize our long list of free resources and amazing tools to put surface mount technology to the greatest use possible.

As a leading name in prototyping and PCB production, we provide buyers with a diversity of resources for all SMT production. We have SMT Solder Paste Stencils available as part of a NEW complete prototyping stencil kit for those who want to do one-off or “by hand” SMT manufacturing and design. Yet, we also have our remarkably advanced design tools that allow for integration of SMT designs.

Surface Mount Technology-Friendly Resources Enable Production

To begin, when a client uses existing Gerber-file designs, or other PCB design programs, the outcome of the production is never left “up in the air” as it might be when a “no-touch” approach is used. This is a serious problem with outsourced or brokered designs in which the schematics are taken and run. Instead, any orders received undergo a mandatory engineering file review before the fabrication process is started. This identifies unusual or even typical glitches in the designs and ensures that a client’s time and money will never be wasted by design flaws or manufacturing flaws or avoidable errors. This also ensures production schedules remain on track.

Other Advanced Circuits surface mount technology-friendly tools include the following free resources:

PCB Artist – Customers of all skill levels appreciate the 100% free access we provide to this innovative PCB design software. Provided as an unrestricted copy of the software, it is capable of up to 28 layers and includes more than 500k parts, a controlled auto-router function, multi-page schematics, and surface mount technology features. Easy to use and 100% free, it is also noted throughout the industry as the very best PCB design tool.

FreeDFM– This software enables clients to run a free and fast design assessment. It works easily and simply and ensures files feature all essential data, automatically corrects some issues, and provides an easy to read and use report. Whether a design features surface mount technology or relies on drilling, it will be as error and glitch-free as possible after running through this feature. Using it also comes with a discount on the work if the designs are submitted through the software. This software converts to Gerber format, takes only minutes, and issues a quote, discount code and link to the PDF of the results.

We proudly make all of our standard and traditional client services readily available to custom clients, too. That means any SMT order will also get that CAM engineer review that ensures that a design of even great complexity will be evaluated and adjusted.

And while this alone is enough for most clients to feel confident and comfortable with an order through Advanced Circuits, there are other services and benefits to partnering with us for PCBs with or without SMT technology. They include:

  • Not a broker – We never sub out our work but instead count on our top of the line, 62k square foot facility and team that guarantee the kinds of quality and speed most want but cannot always receive.
  • No minimum orders – There are no minimum lot requirements, meaning that clients are not forced to invest in huge orders with more PCBs than might be needed. Prototyping is an option – even with SMT features.
  • 24-hour support – Customer service around the clock: this features live tech support that allows design teams to speak directly with a CAM engineer at any hour of the day or night.
  • No tooling charges – When an order features Standard Specifications, we are glad to waive tooling charges and always cancel such fees on reorders of Standard Spec as Custom Spec items.
  • Best shipping record – Advanced Circuits has the BEST ON-TIME SHIPPING RECORD in the industry, and is now shipping 50% of orders early! In fact, we say we “put our money where our mouth is . . . and we ship Standard Spec orders on time or they’re FREE!”

We also point out our decades of stability as a wise reason to work with us. After all, with more than 25 years in the field, and a tremendously healthy bottom line, we are among the most stable providers. We have a vast and fully-capable plant offering design, production, assembly and shipping services, and we emphasize efficiency at all levels.

As a client, you also enjoy the use of a personalized client page. Here you can look through past orders, see the specs and details, look at quotes from other jobs, and even review hold notices, test certifications, and a long list of other helpful reports.

One-Offs or Thousands of PCBs: Advanced Circuits Delivers Unrivaled Quality

The use of such a streamlined process as surface mount technology should never come with punitive pricing and complex or risky production requirements. Clients should be able to send in designs and have them expertly reviewed and corrected, rather than crossing their fingers with a “no-touch” approach to manufacturing. Advanced Circuits takes prototypes and one-offs as seriously as we do batches of thousands of PCBs. Clients can feel confident that basic to complex jobs will be done quickly, efficiently and as fully-supported as needed.

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SMT Manufacturing Made Simple with Advanced Circuits PCB Design and Production /blog/smt-manufacturing-made-simple-with-advanced-circuits-pcb-design-and-production/ Wed, 08 Jan 2020 19:33:22 +0000 https://dev.4pcb.com/blog/?p=2090 Continue reading ]]> Surface mount technology (SMT) is a design and fabrication process that replaces the through-hole mounting of PCB (printed circuit board) components with direct placement on the printed circuit board surface. It is something that is at work in the vast majority of PCB designs tucked inside modern electronics. The computer, phone, TV, and refrigerator someone uses every day is the end result of both SMT manufacturing and PCB production and assembly.

However, the creation of PCBs with SMT manufacturing is quite complex and demands the use of advanced tools and technologies. DFM, or design for manufacturing, as an example, is the “coupled” process that integrates the basics of the PCB and takes into consideration the SMT manufacturing phases as well as the functionality of those SMT processes.

Will the design work as is or will there be a reworking of the PCB necessary? This is one of the major questions asked at the preliminary or prototyping phase, and often the SMT manufacturing component takes the back seat. However, as a design makes its way through the approval processes, SMT manufacturing has to enter the equation. Not only because it is essential to the actual function of the end product, but because it is such a cost-effective measure when hole-drilling can be eliminated.

The benefits of opting for SMT manufacturing include:

  • Cost-cutting – The time and complexity of drilling is eliminated when surface mounting can be used instead
  • Capabilities increased – The weight of a PCB that uses SMT manufacturing rather than drilling and soldering pastes means that the capabilities are improved, too. The era of the smaller and smaller device means that this design capability can open many previously closed doors.
  • Automation – It makes sense to leverage the ability to mass-produce PCBs that retain performance and quality, and SMT manufacturing is a key approach to consistency when producing in mass quantities.

Of course, when considering SMT manufacturing, it also means being able to simultaneously ensure that the design is easily produced and effective. This is where Advanced Circuits can step in and make all of the difference. We have a nearly flawless system that alleviates design flaws in the pre-production process, and helps to cut down on rework that is often the bane of SMT manufacturing.

PCB and SMT Design Resources Bring Optimal Outcomes

Advanced Circuits is a well-known name in the PCB and Prototype Assembly industries. We can handle PCB manufacturing (fabrication) and assembly, including SMT designs.

We are a full-service provider with more than two decades in the field, and give clients exclusive services that support a project of any complexity or simplicity – whether a one-off prototype or a design with SMT and mass production requirements. The resources we make available for them include:

PCB Artist – Customers of all design levels love the free access we provide to this innovative PCB design software. Unrestricted, it is capable of up to 28 layers and includes more than 500k parts, a controlled auto-router function, multi-page schematics, and more. Easy to use and 100% free, it is also noted throughout the industry as the very best PCB design tool.

FreeDFM– This software enables clients to run a free and fast design assessment. It works easily and simply by using uploaded design files, then the program ensures files feature all essential data, automatically corrects some issues, plus provides an easy to read and use report. Using it also comes with a discount on the work if the designs are submitted through the software. This software uses Gerber format, but it takes only minutes, then a quote, discount code and link to the PDF of the results will appear.

All orders undergo a mandatory engineering file review before the fabrication process is initiated. This guarantees that glitches part of the typical “no-touch” approach will not occur, and that time and money will never be wasted by design flaws or manufacturing problems (i.e. rework issues) that could have been avoided.

End Reworking, Delays, and Clunky Design

Worried that learning the free software will take too long or ask too much before showing you how to integrate SMT into your designs? No need to worry, because the PCB Artist software we offer comes with printable tutorials and video options that walk even a beginner through the complex process of PCB design and manufacturing. And when the files are ready, the PCBs can be ordered directly through the software.

And, while the free PCB design resources made available on our site are enough to make us a premier and preferred provider, there are many other reasons to buy PCBs that incorporate SMT manufacturing from Advanced Circuits, including:

  • No minimum orders – There are no minimum lot requirements, meaning that clients are not forced to invest in huge orders with more PCBs than might be needed. Prototyping is an option – even with SMT features.
  • 24-hour support – Around the clock customer service features live tech support that allows design teams to speak directly with a CAM engineer at any hour of the day or night.
  • No tooling charges – When an order features Standard Specifications, we are glad to waive tooling charges and always cancel such fees on reorders of Standard Spec as Custom Spec items.
  • Not a broker – We never sub out our work bt instead count on our top of the line, 62k square foot facility and that guarantee the kinds of quality and speed most want but cannot always receive.
  • Best shipping record – Advanced Circuits has the BEST ON-TIME SHIPPING RECORD in the industry, and is now shipping 50% of orders early! In fact, we say we “put our money where our mouth is . . . and we ship Standard Spec orders on time or they’re FREE!”

With so many reasons to choose Advanced Circuits, and with all of our free PCB design tools and resources available, it makes good sense to get in touch with us today. Our instant quotes and easy order tracking mean that a manufacturing or electronics firm of any size can obtain top quality PCBs designed flawlessly and to precise specifications. We also make SMT Solder Paste Stencils available as part of a NEW complete prototyping stencil kit for those who want to do one-off or “by hand” SMT manufacturing and design.

 

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What is Surface Mount Technology? /blog/what-is-surface-mount-technology/ Fri, 11 Nov 2016 23:16:30 +0000 http://dev.4pcb.com/blog/?p=1133 Continue reading ]]> Surface Mount Technology (SMT) is the widely-used alternative to older through-hole (TH) printed circuit board design and manufacturing practices. While TH fabrication still has its place, SMT has largely taken over where size, weight, and automated manufacturing processes are considerations.

SMT incorporates the use of surface mount devices (SMDs) that replace larger, heavier, and more cumbersome counterparts used in through-hole PCB construction. Today an increasing majority of PCB devices are available as SMDs or packages, making the adoption of SMT board designs and manufacturing practical and cost-effective.

Surface Mount Technology has facilitated the application of electronics for functions that were not practical or even possible with older through-hole fabrication techniques.

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SMT Assembly Considerations

Due to the very nature of SMT board construction and smaller, lighter components, automation of PCB construction is facilitated and becomes very efficient for manufacturing, especially for mass production. To gain the most significant advantage in fabrication, SMT construction must be as highly mechanized as possible.

Assembly advantages in SMT manufacturing are numerous:

  • Hole drilling is nearly or totally eliminated, with the SMDs being connected directly to the board surface.
  • Reliability is enhanced, since there is no requirement to fit component leads through holes for subsequent soldering in place. Soldering SMDs to surface pads is simpler and faster, reducing assembly time while also improving quality.
  • Through-hole fabrication required careful alignment with drilled holes, and often pre-forming of the leads to accommodate specific PCB layout and component placement. SMT assembly eliminates the majority of SMD placement intervention, allowing for more automation and thereby reduced cost. SMDs have smaller leads, or may have none at all.
  • SMT assembly is highly automated, speeding production and reducing turn-around for customers.

Discover Advanced Circuits SMT & Full Range of Capabilities

 

How Does SMT Assembly Work?

In a simplified view of SMT manufacturing, fabrication generally consists of several highly-automated processes:

  • Board material contains solder pads without holes, to which solder paste is applied with a screen-printing-like process. Solder placement can be controlled through the use of a precise stencil template for the individual PCB being fabricated, to apply the material only where needed.
  • Automated component picking and placement machines then position the desired SMDs and other components on the boards precisely, often fed to the machines on reels or tapes, or delivered in static-free media, in the case of components such as integrated circuits.
  • Boards then continue to soldering operations (ovens) which heat the solder pads to the point where the applied solder paste melts and bonds the components to the board.
  • When both sides of the board are being utilized for components, the placement/soldering processes are repeated for the reverse side.
  • Where heat-sensitive components are incorporated on the PCB, these may be installed after the automated soldering, either manually or through processes that would not damage the component.
  • Boards are subsequently “washed” to remove excess flux or solder residues that could cause shorting of components due to their extremely close placement tolerance.
  • Finished, cleaned, and dried products are then ready for final inspection of quality including missing components, alignment issues, or soldering issues that could generate potential problems.
  • Inspections of SMT boards can also be automated. Equipment is available that retains a visual image of the correct board construction, and compares the boards produced to the reference image. Deviations can then be brought to the attention of the machine operator for action or more detailed manual inspections.
  • Inspected boards then proceed to any required testing of circuits and functionality.

Take Advantage of Advanced Circuits’ Quick Turnaround Services

 

Other SMT Fabrication Considerations

SMT manufacturing offers maximum flexibility in building printed circuit boards:

  • Increased automation
  • Improved reliability and performance
  • Reduced manual intervention for component placement
  • Nearly total elimination of hole drilling operations
  • Smaller, lighter boards
  • Ease of assembly, using both sides of the board without the hole limitations that exist in through-hole construction
  • Ability to co-exist with through-hole components, even on the same board
  • Increased density – more SMD components in the same space, or the same number of components in a much smaller footprint.

Highly-automated SMT assembly equipment can fabricate PCBs very efficiently, while maintaining reliability and quality. Machines today are capable of placing components at a rate of 25,000 per hour or more.

With the many advantages provided by SMT construction and assembly processes, the highly-specialized manufacturing equipment required for fabrication can be cost-prohibitive to many companies. This is why many companies that design SMT PCBs rely on third-party specialized resources for actual manufacturing of the boards they have designed.

Place Your PCB Order Now

 

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