Introduction

Surface finishes are crucial in PCB production. They guarantee peak performance and shield exposed copper traces. These finishes are a barrier to oxidation, and they facilitate soldering connections that are reliable. They have a direct impact on the longevity and performance of electronic gadgets. Two common surface finishes have arisen as a result of their distinct benefits and drawbacks: Electroless Nickel Immersion Gold (ENIG) and Hot Air Solder Level (HASL).

The HASL method involves submerging the PCB into molten silver, followed by a step of hot air drying. In contrast, ENIG entails putting a small coating of gold after a nickel layer. A careful choice between HASL and ENIG can have a significant impact on the solderability, shelf-life, and overall reliability of a Printed Circuit Board.

AssemblePCB provides expert services for PCBA. This covers the application and choice of various surface finishes, such as Electroless Nickel Infusion Gold (ENIG), Hot Air Solder Leveling (HASL), or advice on which finish is ideal.

1. HASL VS ENIG–HALL

1.1 Definition

Hot Air Solder Leveling (HASL) is commonly abbreviated as ‘HASL’. This is a surface finish that’s used in the printed circuit board industry to provide a long shelf life as well as a reliable solder joint. hot air soldering leveling makes it easier to solder a component. Initially, HASL is applied as a finish to improve solderability. It also covers exposed copper circuitry.

HASL VS ENIG – HASL

1.2 HASL Finished

The HASL has been a popular surface finish for many years, with advantages such as low cost, repairability, and availability.

As we have discussed, HASL offers a surface finish that is solderable and has a long shelf life. The printed circuit boards are submerged in a container of molten metal solder to coat the copper surfaces during the HASL process.

Then, using the hot air knife to level the circuit board and remove excess solder. The printed circuit boards must be covered or the copper will oxidize, making the board useless.

Copper finishes are found on the printed board. This finish creates an interface between the printed board and the component.

 

2. HASL VS ENIG–ENIG

2.1 Definition

The ENIG acronym stands for Electroless Nickel Infusion Gold. Because it is composed of electroless nickel plating with a thin coating of immersion gold, the ENIG gets its name. Hot air solder leveling is a surface finishing used in the printed circuit boards industry. It has consistently gained market share due to its flexibility in different component assembly processes.

HASL VS ENIG – ENIG

2.2 ENIG Finish

The two-layer finish is a metallic coating consisting of an electroless layer that is coated with immersion gold. During storage, the nickel serves as a barrier for the copper, and the immersion gold shields it. ENIG has become one of the most popular surface treatments in the printed circuit board industry due to its advantages.

2.3 ENIG Plating

In the early stages, ENIG plating is not reliable. This type of leaf has reliability problems. Electroless immersion nickel-gold is not uniformly wetted, unlike hot air solder leveling. The copper pads have been separated from the finish as a result. The nickel ions in the reducing agent must be replaced to ensure the coating is at the right temperature and concentration.

 

3. Advantages and Disadvantages of HASL and ENIG

We have already discussed the two finishes. In essence, hot air solder leveling (HASL) possesses certain distinct advantages over electroless nickel immersion gold (ENIG), and the reverse is also true. In this, section we will describe each surface finish and its advantages and disadvantages. Note that there is no surface finish without its disadvantages. Therefore, choosing a surface finish depends on the application.

3.1 Advantages of the HASL

Hot air solder uniform process type HASL is widely used on the surface of printed circuit boards in the PCB Industry. Its use has many advantages:

• The printed circuit board can be exposed to temperatures as high as 265°C. Before any components are attached to the printed circuit board, any potential issues can be found by exposing it to this degree of weather.
• It is easy to operate the hot air solder leveling.
• This is a surface finish which is affordable.
• hot air solder leveling has a reputation for offering a long-lasting storage life.
• It is widely available. It is a great alternative to other surface finishes.
• A flawless wetting during the soldering or connecting of components.
• The components must be wetted perfectly before joining or soldering.
• Visual inspection is possible for this type of surface finish.

Multi-Layer PCB with HASL

3.1.2 Disadvantages of the HASL

According to one viewpoint, every benefit is always connected to a disadvantage. Every kind of surface finish has advantages and disadvantages. Among the flaws in the hot air solder leveling that have been found are:

1. Because hot air solder leveling involves uneven surfaces, this kind of surface finish is not appropriate for Surface-mount technology (SMT).
2. In keeping with the first point, it is not eligible for fine pitch. In order to improve flatness, horizontal levelers are necessary.
3. HASL has some limitations that make it unsuitable for manufacturing when it comes to boards that are also thick or thin.
4. Due to the high temperatures involved in their production, printed circuit boards can suffer from some disadvantages.
5. unable to tolerate the plated holes’ strict tolerance.
6. Line binding is not suitable for hot air soldering leveling.
7. Using this surface finish at high temperatures may cause the plated through holes to break.

3.2 Advantages of the ENIG

• The electroless nickel immersion gold provides a flat surface in contrast to the hot air solder leveling method.
• This type of surface finish is well-suited for plated through holes.
• Similar to hot air solder leveling, it has a long shelf life.
• No lead
• This surface finish can be used as the bottom metal of cob wire.
• ENIG exhibits exceptional electrical conductivity.
• Electroless nickel immersion gold (ENIG) is well recognized for its resistance to oxidation.

Electroless Nickel Immersion Gold Surface Finish

3.2.1 Disadvantages of the ENIG

1. The cost is a major issue.
2. In contrast to hot air solder leveling (HASL), electroless nickel immersion gold (ENIG) is not amenable to rework.
3. Signal loss is a problem with electroless nickel immersion gold
4. ENIG is more complex than HASL.
5. ENIG’s low strength makes it vulnerable to the black pad

4. Other Surface Finish Process

4.1 OSP

OSP stands for Organic Solderability Preservative. Also known as anti-tarnish, the organic solderability preserver is an organic preservative. This surface finish protects copper’s surface from oxidation. This is achieved by applying a thin layer of material to the copper surface using a specific process. This finish is made with organic compounds, usually water-based, that bond to the copper. The result is a metallic and organic layer that protects the copper before soldering.

Organic Solderability Preservative

4.1.1 Advantages of OSP

• In contrast to hot air solder leveling (HASL), organic soldering preservatives deliver a flat surface.
• The process involved in organic soldering preservatives is comparatively straightforward.
• It allows for rework.
• It guarantees an extremely smooth surface.
• It serves as an excellent option for surface mount technology (SMT).
• It is well-suited for lead-free soldering processes.
• This type of finish is economical.
• It ranks as a top choice for horizontal production lines.
• It presents no hazard to the environment.
• It can be combined with other surface finish types on a single panel.

4.1.2 Disadvantages of OSP

1. After multiple soldering cycles, the film becomes damaged.
2. It is unsuitable for electrical measurements.
3. It is incompatible with plated through holes.
4. Unlike the aforementioned surface finishes, OSP has a short storage or shelf life.
5. It demands careful handling.
6. Its thickness cannot be measured.
7. It has strict storage condition requirements.

4.2 HARD ELECTROLYTIC GOLD

This type is composed of a gold sheet that has been coated with a nickel barrier coat. This type is only known as “hard-gold.” The majority of its applications are commonly found in keypads, connector fingers, and other areas. Its ability to vary in thickness is one of its main advantages over electroless nickel immersion (ENIG). Hard gold is generally expensive and has a low soldering capability.

Printed Circuit Board (PCB) with GOLD

4.2.1 Advantages of hard gold

• It is a durable and reliable surface.
• Storage life of hard gold is good
• No lead

4.2.2 Disadvantages of hard gold

1. This surface finish type is expensive.
2. It calls for extra processing steps.
3. Etching damage may lead to flaking.
4. Hard gold utilizes resist materials.
5. It has soldering limitations: it cannot be soldered beyond 17µin.
6. Aside from finger areas, this finish does not encapsulate trace sidewalls.

4.3 IMMERSION TIN

This is a metallic finish applied directly to the metal on the printed circuit boards. It is a metallic finish that prevents oxidation and has a long storage life. We’ll take a look at some of the benefits and drawbacks associated with immersion tin.

4.3.1 Advantages of the immersion in

• The immersion tin can be reworked
• Press-fit pins can be inserted easily with this product.
• The immersion tin is free of lead
• It provides a flat surface

4.3.2 Disadvantages of the immersion in

1. It is not an appropriate option for assembly processes.
2. Measuring its thickness is somewhat unfeasible.
3. Uncovered tin tends to corrode during the final assembly stage.
4. This method utilizes agents or substances with carcinogenic properties.
5. It tends to incur processing damage rapidly.

4.4 IMMERSION SILVER

Immersion silver has pros and cons when compared with other surface finishes. In some cases, it’s considered to be a superior surface finish.

4.4.1 Benefits of Immersion Silver

• The associated process is straightforward.
• Immersion silver provides a flat surface.
• Immersion silver stands as a top choice for high-quality traces.
• It is cost-effective.

4.4.2 Disadvantages of immersion silver

1. There may be some micro-hole problems
2. The water can easily be polluted

4.5 NICKEL PALLADIUM (ENEPIG)

From a historical perspective, ENEPIG is not a particularly long-established surface finish process within the PCB industry. Typically, ENEPIG is widely used in the semiconductor sector, and it is also applied to the combination of aluminum and gold.

Printed Circuit Board PCB with ENEPIG

4.5.1 Advantages of ENEPIG

• Unlike electroless nickel immersion gold (ENIG), it does not have the black plate issue—meaning there is no nickel corrosion.
• It is an excellent option for lead-free soldering processes.
• ENEPIG boasts a favorable shelf life.
• It is an ideal choice for gold wire bonding.
• It is more cost-effective compared to electroless nickel immersion gold (ENIG).
• It is suitable for a wide range of surface finishes.

4.5.2 Disadvantages to ENEPIG

1. Its function is complex, unlike some of the other processes that were mentioned.
2. This type of process is still relatively new and has not been well established.

5. Conclusion

Merge Your Plans

While several options have been discussed, the cost of each has not been excluded from consideration. One aspect involves planning to use a surface finish, and another entails carefully selecting the appropriate type that is perfectly suited to your project. For your benefit, it is advisable to assess your project first before determining which surface finish to adopt. If you are working with a limited budget, opting for a surface finish like hot air solder leveling (HASL) is recommended; however, if you choose HASL, you must keep in mind that it is not suitable for RoHS-compliant products.

It’s time

We’ve shown you some common surface finishes, along with the benefits and drawbacks of each. We can guide you to the end of this project, which we have begun. We are available 24/7 to help you. Contact us today! We’d love to hear from you. You can also request a quote, and please do not hesitate to send us any questions or concerns.

Concerned about the expense of PCB assembly? Precise PCB assembly estimations are crucial. Being aware of this can lower your expenses.
You can use this advice to make well-informed judgments on cutting PCB assembly costs.

1.  8 Key Factors Influencing PCBA Cost

1.1 PCB complexity

（1） PCB layers

Single-layer and double-layer PCBs are the least expensive. Due to increased material prices and routing complexity, multilayer PCBs are more costly.. According to the general belief, PCBs cost increases with increasing layers.

（2） Dimensions PCB

The size of the PCB determines its cost. The more space there is on the PCB, the easier it will be to add components and circuits for the intended purpose. Larger PCBs are more expensive because they can be used for large and medium devices. Smaller PCBs need fewer parts and are less expensive. As the PCB grows in size, the assembly costs increase.

（3） PCB minimum hole diameter

Drilling requires a drill bit. Compared to drill bits with lower diameters, standard drill bits are less costly. Drilling costs go up when the hole diameter is smaller.

（4）Trace Width

To get smaller gaps or traces, we’ll need to employ laser drilling or certain etching methods. Additionally, production and tooling costs will rise..

（5） PCB Thickness

The cost of assembly increases with board thickness. Drilling holes in large boards requires precision and complex equipment. The cost of custom-made assembly panels for PCBs with non-standard sizes will increase.

（6） PCB Substrate Material

The material of the PCB substrate may have a significant effect. Materials such as FR-4 are extensively used and reasonably priced. Those substrates that are more expensive include ceramics and flexible materials.

Flexible PCB                        FR-4 PCB

 

（7） PCB Solder Mask Color

Standard colors like green are the least costly. Custom colors cost more.

（8） Surface Finishes on PCBs

The cost of various PCB surface treatment techniques varies.

• HASL: An inexpensive method that is less accurate.
• Impression tin/silver: This is reasonably priced. The boards have a limited shelf life, which can affect inventory and assembly time.
• ENIG: The gold plating is what gives ENIG its highest rating. This is perfect for wire bonding or high-reliability applications. The thickness of immersion gold increases its cost.

HASL      Immersion tin      ENIG

1.2 components and bill of materials (BOM)

The choice of components and the bill of materials are crucial determinants of PCB assembly costs.

(1) Purchase Price of Components

During shortages, we could have to spend extra money on components. The cost of BOM will rise sharply.

It’s possible that components from well-known brands cost more than those from other brands. They are more reliable and safer. Orinew products are original.

(2) Density and Quantity of Components

Each additional component will increase the time it takes to pick and place. Boards with a lot of components may require more programming time and even nozzle replacement. Depreciation and increased labor costs are the outcomes.

Densely packed components are subject to stricter design and placement guidelines. As a result, there is more rework and less yield.

(3)Component Type & Packaging

• Surface Mount Device (SMD). Assembly costs Through Hole Device (THD). assembly costs

SMD component assembly can be cheaper. The automatic placement machine increases manufacturing efficiency by processing a large number of components rapidly. Wave soldering and manual soldering are both used to solder through-hole components. Lead must be inserted into the holes, among other procedures. These need more time and effort.

THT VS SMD

• Package Complexity and Assembly difficulty

BGA/LGA/Flip Chip: Precise placement, X-ray inspection of the solder junction, and underfilling are necessary for these high-density packagings. Boards can have higher inspection costs or special processes.

Some components that do not conform to standard shapes require manual positioning or even special tooling. The result is increased setup costs and slower production.

1.3 Order Quantity

The quantity of boards you order determines the pricing per PCB.

• We can expect to pay a lot if we only need a few prototypes. There will be additional setup fees. For small batches,Orinew charges RMB 200–300; for medium batches, RMB 300–400; and for large batches, RMB 500.
• The unit price for bulk orders will be lower. The engineering fee is not required. The cost per unit will go down as we produce more units.

1.4 Assembly Processes Technology

(1) SMT Process Cost

• Stencil Costs and Model Costs: It is important to know that stencil fabrication costs are also included. When we place large purchases, we will be billed for the cost of the models and test fixtures.
• SMT placement cost: The cost of the patch is determined by the quantity of soldering sites. The amount of soldering needed increases with price. In the long term, machine placement is cheaper.

(2)Cost of DIP post-welding processing

The quantity of holes has an impact on the cost as well. The more holes there are, the higher the price. There are two distinct pricing situations.

• Wave soldering: The circuit board is capable of handling temperatures as high as 250 degrees. Soldering machines can be used by operators.
• Manual Soldering: The circuit boards cannot handle the high temperatures generated by wave soldering. Soldering the circuit board’s components by hand is required. The labor cost is high. Wave soldering, in comparison, is cheaper.

 

(3) Cleaning of PCB

It may be more cost-effective to leave the residues. Residues can raise the cost of rework and interfere with testing. However, cleaning the PCB will result in short-term cost increases. It is still beneficial to inspect later. It can also reduce the rate of rework.

 

(4) Input Program Testing

We sometimes provide our own software for testing to the assembly plants. This includes the loading of software, functional verification, and system debugging. For the test, it could be required to recruit extra workers or buy more equipment. Costs of equipment and labor will increase.

1.5 Inspection and Testing

PCB assembly is not possible without testing and inspection, which are expensive. We mention X-Ray, AOI, and power-on tests, as well as other essential testing. Testing can help you find problems faster and save a lot of time later.

 

1.6 Hidden Fees

(1)PCB Depaneling Price

Separating PCBs from panel structures also incurs a cost. Board thickness is one of several elements that affect the cost of removing PCBs from the panel structure.

• Depaneling costs are generally higher for PCBs with thicker substrates.
• Standard layouts are typically less expensive to depanel than complex shapes.
• Depaneling standard PCB substrates is generally less expensive than depaneling high-performance substrates.
• Low-volume production typically costs more per unit than high-volume batches.

(2)Package Price

Anti-static bags and other protective packaging solutions are also expensive. Customized packaging is usually more expensive for large orders. Sorting and labeling, whether manual or automated, will incur additional costs. Costs are associated with developing packaging that meets industry standards (e.g., IPC Standards).

 

(3)Expenses for logistics

Costs of logistics include both domestic and foreign transportation. Multiple factors influence prices, including distance, weight, and volume.

(4)Lead time Costs

Orders with normal processing times are subject to standard pricing. Rush orders often incur additional charges due to the accelerated handling.

 

2.Five Proven Strategies for Reducing PCB Assembly Costs

We now know the breakdown of PCB Assembly costs. We will now explore ways to cut costs without compromising on quality.

2.1 DFM Optimizer

(1) Optimization of Layers: Streamline the circuit design by minimizing PCB layers. To achieve cost-effectiveness, balance functionality and layer count.

(2) Avoid exotic features: Limit blind/buried vias, controlled impedance, or HDI to critical areas. Standard FR-4 should be preferred over specialty substrates wherever feasible.

(3)Component Uniformity: Choose standard SMD package dimensions. Reduce stencil complexity during assembly and reduce changeover costs.

(4)Ensure Adequate Spacing: Ensure that components are spaced enough apart. There is less soldering, AOI inspection, and rework.

(5)Panel design: Increase the number of panels and improve material use. Costs will be cut as well.

 

2.2 Controlling Costs for Bill of Materials (BOMs).

(1)Dual Source Strategy: Qualify 1-2 alternative suppliers of critical components. This can reduce price fluctuations and supply-chain disruptions caused by sole-source vendors.

(2) Optimization of Tolerance: Select passive parts with a larger tolerance when performance allows. This can lower component costs.

(3)Standardization of BOM: Reduce component diversity through the use of common parts. It can simplify procurement and reduce overhead.

(4)Bulk Procurement: Aggregate the material requirements across all projects to meet MOQs. It is possible to get volume discounts by centralizing purchasing.

2.3 Process Enhancement

(1)Assembly Simplification:

Where possible, opt for SMT components over THT designs. Reduce labor costs by eliminating manual/wave soldering.

(2)No-clean Soldering:

Lead-free solder paste can be used to eliminate the need for post-soldering cleanup. Production times and cleaning expenses can be decreased.

(3)Standardize test fixtures:

Replace ICT fixtures that are custom-made with universal test platforms. Reduces the upfront costs of test setup and speeds up debugging.

• Risk-Based Testing:

For products with low risk, test AOI instead of 100% on samples. Quality assurance and cost-efficiency should be balanced.

 

2.4 Work with Full-Service Manufacturers

Understanding the drivers of PCB assembly costs is crucial. Assembling PCBs with the best PCB assemblers will ensure quality and timely delivery. Selecting a reliable, experienced assembly partner is crucial to success.

(1)One-stop service advantage: Prioritize PCB and PCBA manufacturers that offer integrated fabrication. The quality-controlled processes that they offer reduce the risk of product failures or rework.

(2) Sourcing Strategically: Chinese manufacturers offer cost-effective options for high-volume orders. Orinew provides affordable prices without sacrificing quality. Local suppliers can minimize costs and lead times for small or urgent orders.

 

2.5 Packaging and Logistics Optimization

(1)Packaging Standardization: Replace customized trays with generic ESD bags for PCBs that are not fragile. Packaging costs are reduced without compromising ESD safety.

(2)Strategic Shipping: Choose rail or sea freight instead of air for large orders. For goods that are not urgent, it is an excellent method to lower transit expenses.

 

3.Mitigating Common Risks

(1)Overlook Hidden Costs: Don’t underestimate costs like certification and compliance. These “invisible costs” often exceed 15 percent of the total assembly fees.

(2)Quality-Cost Tradeoffs: Defect rates from low-cost vendors may raise long-term costs.  Give preference to suppliers with established quality control systems.

(3)BOM accuracy: To prevent delays, make sure the bill of materials (BOM) is complete. Use automatic BOM verification tools to cut down on errors.

(4)Process optimization: Avoid excessive automation for small batches. Manual assembly is more cost-effective. Mixed SMT+THT board setups require two lines, which can cause 2+ hours of downtime per day.

 

4.PCB Assembly Costs FAQs

1) Are suppliers able to source PCB assembly components?

Suppliers can manage component procurement, but this will increase costs. We can also source the parts ourselves, provided they are compatible with solder.

2) What is the cost of a PCB prototyping assembly?

The cost of a prototype depends on the number of layers, the complexity of design, and types components.

3) What can be done to minimize the amount of waste components during PCB assembly?

Organise the components in accordance with the sequence of assembly. It reduces the number of errors made during testing and placement, reducing material waste.

4) How to avoid hidden charges in PCBA quotations?

Testing or expediting charges are often hidden costs. Request quotes that include detailed BOM breakdowns, and compare component prices across suppliers to avoid any surprises.

5) How does solder paste affect PCB assembly cost?

Yes. Solder paste of high quality reduces the number of defective solder joints and the rate of rework, which has an indirect effect on overall costs.

6) Are through-hole components soldered with SMT machines?

No. No. SMT equipment was designed only for surface-mounted parts. THT is required for through-hole components.

7) In China, why are PCB assemblies cheaper than in the US?

China’s competitive advantage is due to its lower labor costs, reduced compliance costs, and efficient equipment usage.

8) Does any PCB assembly manufacturer offer free testing

Some suppliers offer complimentary functional testing with large-volume orders.

9) How do manufacturers calculate initial PCB

Three main inputs are required by suppliers. Gerber files are required to determine the design complexity. To price components, they need a BOM (Bill of Materials). They should also be aware of any special instructions regarding lead times, testing specifications, or compliance requirements.

 

5.Summary

Keep in mind that the greatest option isn’t usually the one with the lowest price. Costs should be weighed against delivery deadlines, quality standards and long-term performance. We may use this tool to make well-informed decisions on our project. We wish you success in your PCB assembly projects, now and for the future!

PCB panel refers to multiple small PCB boards spliced together to form a large PCB panel. After the panel production, the PCB panel will be cut into diverse small single boards.
For smaller PCBs and PCBs of various shapes, you can use panelization to improve the production efficiency of printed circuit boards. We recommend using panelization technology for PCBs smaller than 50mm*50mm.

PCB assembly panel refers to mounting electronic components on a blank PCB panel board through SMT mounting equipment.

Assembly panel type

Assembly panels and there are two main types in the SMT mounting process:

• Single-sided PCB panel

Single-sided PCB panels can only be placed on a single-designed printed circuit board. This type of PCB panel is suitable for use on a single larger printed circuit board and small-batch PCB panel board assembly processes.

• Multi-connected PCB panels

Multi-connected PCB panels can lay two or more PCB boards of the same design. The number of PCB boards installed depends on the size of the PCB boards.

Advantages of PCB panels

• Increase productivity

PCB panel boards reduce the number of board changes during the production process, thereby improving production efficiency. PCB panels can also achieve batch-automated production.

• Cut costs

Using PCB panels can reduce board waste and thus reduce production costs.

• Easy to assemble and test

Automated equipment assembly and test PCB panels can reduce assembly and testing difficulty and workload.

• Diversify the design

PCB designers can design different PCB circuit diagrams through PCB panelization technology at the same time. In designing PCB prototypes, we used area division to arrange printed circuit boards to manufacture multiple PCB prototype circuit boards.

• Ensure product safety

PCB panel technology can protect printed circuit boards from mechanical stress, vibration, shock, and other factors during the panel board assembly.

• PCB panel requirement of Assembly

1. The minimum size of a PCB board is generally not less than 50mm*50mm, and the maximum size is not more than 310mm*410mm.
2. When designing the PCB frame, the frame tries to form a closed loop to prevent the PCB panel from deforming during SMT assembly.
3. There should be a space of more than 0.5mm between the electronic components and the edge of the PCB board.
4. Positioning holes should be added at the four corners of the panel edge, and the hole diameter can be 4mm±0.01mm.
5. Wiring or welding is banned within 1mm of the edge positioning hole.
6. When PCB panels are assembled, we should add the reference mark, usually located at the diagonal edge of the panel.
7. when adopting gapless paneling, the distance between the boards is 0. In addition, it is necessary to add process edges on both sides of the assembled board to fix the circuit board during SMT assembly and welding.

Our company’s requirement for process edges is a minimum width of 3mm, and we generally use 5mm.
8. If there are gaps between the boards, the distance between the boards must be greater than or equal to 1.6mm.

9. If you adopt stamp holes for connection, you need to place 5 to 8 holes on the edge of the circuit board and place them in double rows. The hole diameter is required to be 0.6 mm. The distance between holes should be 0.25 to 0.35 mm. The stamp holes can be placed in the middle of the board frame line or extend to 1/3 of the board.

When to Use PCB Panel Assembly

• Small circuit board size

Since many factories now have fully automated production, automated equipment has restrictions on the size of printed circuit boards. Cutting tools cannot be used when assembling small-sized circuit boards. In this case, it is necessary to create a large panel to facilitate circuit board assembly.

• Mass production

When you need to produce PCB boards in large quantities, splicing multiple boards into a large panel and, at the same time, assembling many boards can improve assembly efficiency and save time and labor costs.

• Electronic components close to the edge of the board

If the electronic components are too close to the edge of the circuit board, many problems will occur during the PCB assembly process. For example, uneven solder paste printing, SMT assembly out of range, etc. So, PCB panel board assembly is a safer processing method than single PCB assembly.

If you have any of the above questions, you can contact us at circuitcardassembly. As a PCBA manufacturer, we have decades of rich PCB assembly experience and fully automated production equipment. We have invested heavily in introducing advanced foreign PCB production equipment, such as Berkeley laminators, Hitachi drills, Japanese screen automatic exposure machines, LDI, AOI, etc. These devices can avoid many problems in the production process. If you cooperate with us, you will get high-quality products and more quality services.

PCB panel manufacturing and assembly process

After the PCB panel design is completed, you can find a manufacturer to assemble the PCB panel. The PCB panel assembly process has the following steps:

• PCB panel manufacturing

PCB panel manufacturing uses photolithography. The photoresist is applied to the PCB panel and exposed to ultraviolet light through a photomask. Photoresist contains a chemical that hardens when exposed to ultraviolet light, then etches away unwanted copper to create the desired circuit pattern.

• Solder Paste Printing

Place the PCB panel on a stainless steel plate, and evenly apply solder paste to the pads on the circuit board surface. Then, the SPI machine detects the printing quality of the solder paste and whether there is any tin leakage or insufficient tin.

• SMT Assembly

The automatic placement machine places the surface mount components on the prepared PCB panel and then solders the BGA, IC, resistors, capacitors, and others to the PCB surface through the machine equipment.

• Reflow

The PCB panel is put into a reflow oven for heating, and the solder paste undergoes a process of melting at high temperature and cooling, fixing the electronic components on the board.

• PCB panel testing

After reflow soldering, the PCB panel will undergo testing, such as automatic optical inspection (AOI), X-ray inspection, in-circuit testing (ICT), etc, to detect whether the PCB circuit board capability and quality meet requirements.

• Scoreboard

PCB Scoreboard mainly includes V-shaped scribing, lug wiring, routing, laser Scoreboard, etc.

• Final inspection and packaging

The separated PCBs undergo a final visual inspection to ensure PCBs meet quality standards. They are packaged and shipped to customers.

Summary

Panelization is a critical step in PCB assembly. It can improve efficiency, reduce costs, and ensure consistent quality in mass production. It is necessary to cooperate with an experienced PCB manufacturer throughout the process.

If you need small-volume circuit boards with custom requirements in terms of component packages, component specifications, assembly technologies or levels of density, Assemble PCB is the company to contact. As a reliable assembler and manufacturer of PCBs, we can provide the low-volume PCB assembly services you need at a cost that will fit your budget. Our facility is well equipped for low-volume PCB assembly, as we have multiple assembly lines and can easily modify product requirements and assembly-line specifications in a short amount of time.

Other PCB assemblers may need high-volume orders to offer their best work, but not Assemble PCB. We pay the same close attention to low-volume assembly runs as we do to larger projects. Customer satisfaction is our highest priority, and that means every customer, big or small, gets top notch service and attention. Our in-house quality assurance department will go to great lengths to ensure your PCBs meet your lofty quality and performance standards. Low volume doesn’t mean to compromise product complexity or variety.

We Offer Complete Turnkey Low-Volume Assembly Services

Unlike many of our competitors, we can handle every aspect of your project, including PCB fabrication, component procurement, and PCB assembly, and we can do it at a much lower cost than you will find anywhere in the United States or Europe without quality compromised. We can save you the time and hassle of having to locate and deal with multiple suppliers. Even better, there’s no minimum order quantity required.

Add to that the difficulty of pinning down the person you need to talk to when there’s a problem anywhere in the process. It’s so much easier to have everything under one roof. That’s what you get when you partner with circuitcardassembly. We work with your design specifications, fabricate your prototypes, design your PCBs and finish your low-cost small batch PCB assembly. No running around trying to pull it all together. You tell us what you need, and we make it for you fast, so you can concentrate on the actual business of putting together, marketing and selling your product.

High Mix Assembly to Meet Your Advanced Requirement

Modern electronics tend to call for applications with high density and complexity in order to get more functions achieved. Assemble PCB provides multiple assembly types including PTH and SMT, single/double-sided assembly, and they can be freely combined on one circuit board for advanced functions and applications. Furthermore, multiple component packages and sizes also contribute to high mix assembly. In Assemble PCB, we’re able to deal with components with sizes starting from 01005 and 0201 while component packages involve BGA, QFN, WLCSP etc.

Quality PCB Testing

We want you to be sure you can trust the quality of every assembled printed circuit board that comes out of our facility and goes to yours. We know that you will do your own quality testing, but we also know that unless we’re providing you with high-quality boards to test to begin with, we’re wasting your time, and that’s not what we do.

To ensure our printed circuit boards meet your high performance and quality expectations, we perform a free DFM and DFA check to detect any issues that could negatively impact the low-volume PCB fabrication process. We then conduct function testing based on your specific requirements. If necessary, we can build a PCB prototype for function testing purposes.

Attentive Customer Support During Every Phase of Your Project

Contact us anytime to discuss your small quantity, low-cost printed circuit board assembly project, your PCB prototypes or about any concerns or questions you might have. Our world-class customer support team is available to answer your questions and address your concerns. We’re proud of our high-level customer service responsiveness. We’ve achieved a remarkable 99-percent customer satisfaction rating and an impressive on-time record that many large firms are unable to replicate.

We’re Always Ready to Discuss Your PCB Assembly Project

When it comes to low-cost printed circuit board assembly, Assemble PCB is the only logical choice. We pay the same care and attention to our small quantity PCB assembly work as we do to all of our PCB fabrication and other PCB-related services.

If you have a low-volume PCB assembly job, we can handle it right now with quality and value you won’t get from other PCB suppliers. Click the button below to submit RFQ for your custom printed circuit board assembly demand. We’ll give PCB Assembly price within one to two business days.

If you want to discuss possibilities of your PCB Assembly project, sign off NDA or have other special concerns, feel free to reach us here. Just let us know how to serve you, we’ll get you taken care of.

The term “turnkey” generally refers to any product or service that is sold to the buyer in a form that is ready for immediate use. When applied to PCB assembly, turnkey means that the supplier handles all aspects of PCB solutions, including components procuring and PCB manufacturing, picking and placing components on specific locations on your custom PCBs. In essence, full turnkey PCB assembly gives the buyer greater freedom to focus on PCB design, while the supplier takes care of the rest, which is why it is a leading form of one-stop electronic assembly.

As one of few quality-focused PCB manufacturers that include electronic assembly services, Assemble PCB has more than 10 years of experience in providing fast, reliable turnkey PCB assembly services for more than 10,000 companies from over 80 countries around the world. Our single-source approach saves you time and money, while also ensuring more reliable, consistent results than when dealing with several suppliers.

Additionally, our professional team can skillfully manage your entire project from concept to delivery, and make the entire electronic assembly process as smooth and seamless as possible.

Advantages of Full Turnkey PCB Assembly Services

• Shorter Lead Time

As a fundamental form of electronic assembly, PCB assembly primarily contains three phases: PCB fabrication, components procurement and PCB assembly. Traditionally, you should quote and confirm design files with sales and engineers working for your PCB manufacturer, then components distributors and finally PCB assemblers. Such series of quotations and confirmations just need your time spent in contacting with different partners. If those partners are from different countries, you have to overcome some problems such as time zone, communication habits etc. Full-turnkey PCB assembly, however, is a highly-efficient form of electronic assembly. As soon as full-turnkey PCB assembly is determined, an overall assembly quotation and indispensible issues prohibiting smooth manufacturing will be raised so that three times of communication have been cut to one time with electronic assembly efficiency dramatically improved.

• Lower Cost

Another advantage of full-turnkey PCB assembly service is overall cost reduction. Pack-up service is usually cheaper than separate ones as far as electronic assembly is concerned. At least, freight fee will be saved because you don’t need to get manufactured PCB boards and electronic components delivered to assembly workshop. Moreover, components procurement may get easy and customer-friendly because experienced electronic assemblers are usually able to provide reliable components with relatively low cost based on their long-term cooperation with parts manufacturers or distributors.

• Transparent Monitoring

When it comes to electronic assembly process, it’s significant yet difficult to monitor your products’ manufacturing stage as it is totally related with your products’ performance and time to market. Full-turnkey PCB assembly allows engineers at each stage to be aware of what they’ve accomplished and to better understand their status for better performance of final products.

Who Can Benefit Most From Our Turnkey PCB Assembly Services?

Now that full turnkey PCB assembly allows PCB designers to make better use of their time to focus more on PCB design, it works perfectly on companies striving for frequent upgrading and refreshing of products. They need to dig into deeper market by providing multiple creative electronic products and they strongly call for a steady and smooth electronic assembly process.

Turnkey printed circuit board assembly is also an ideal electronic assembly solution for small businesses or startup companies that want to bring smaller quantities of assembled PCBs to market without having to invest in or carry an extensive inventory. It also offers a more cost-effective, efficient means of assembling and testing PCB prototypes for new products. In addition, quick-turn PCB assembly service makes sense for any company that needs to receive their circuit boards with the shortest possible lead time.

Quote for Your Turnkey PCB Assembly from Assemblepcb

Another important benefit of being a circuit Card Assembly turnkey PCB assembly client is the ease of quoting online. With your project specifications and desired quantities filled at our quote form and then submit,we will reply you very quickly with the price. To provide better electronic assembly services, we’ll store your information in the cloud, which enables timely, convenient reordering of your circuit boards. Try for yourself by clicking the button below and submitting a quote request.

If you have any question on our full turnkey PCB Assembly service, our salesman are happy to guide you through. Reach us here for a quick response.

Consigned PCB Assembly

With a consigned PCB assembly process, you supply us with all the parts and components required for your circuit boards, while we handle the fabrication and assembly for you. A consigned PCB assembly process makes sense if you manufacture proprietary or highly expensive products featuring unique parts that are difficult to replicate. It can also be a smart cost-saving move if you have a large backlog of parts in your inventory. We have the expertise to use your parts to produce a custom PCB assembly that meets your exact specifications.

Partial Consigned PCB Assembly

An alternative to a fully consigned PCB assembly is a partial PCB assembly consignment. A partial consigned PC assembly offers a hybrid solution: you supply some of the parts used in the assembly, while we furnish the rest. As with a complete PCB assembly consignment, we perform the fabrication of your boards along with full assembly. This option can work well if you are only able to manufacture or locate some of the parts on your own, or if you want parts that offer a higher level of quality. We only use parts from reputable sources that meet our stringent quality control standards.

Note: We accept SMT parts for partial consigned PCB assembly in the following formats: reels, tubes, trays, partial reel, cut tape and bulk.

Why Choose Consignment Services from Assemble PCB?

When you select Assemble PCB for your consigned or partial consigned PCB assembly projects, you get the benefit of our highly competitive pricing that will minimize your overall production costs. We also offer IC programming, custom testing and free DFM checking. Our entire soldering process is lead-free, making it safe and eco-friendly. What’s more, you will experience the high level of service and support that has helped us attain a remarkable 99% customer satisfaction ranking.

Custom Quotation is Always Free

Want an estimated cost for your custom circuit boards assembly project? Simply click below button to submit a RFQ for your project. We will give the PCB assembly price within 1-2 working days.

Interested in our components sourcing service, prefer mailing components to our office for assembly, or want more info about how Assemble PCB processes consigned assembly project? Please feel free to contact us for more details.

Benefits of PCB Prototype Assembly

The reason for ordering a PCB prototype, it’s because that you want to quickly assess how well your PCB design is going to work. You cannot do that without going through the assembly process. Fortunately, circuitcardassembly can do your PCB prototype assembly in-house, so you can find out quickly just how well your assembled PCB prototype works.

There’s no need to fabricate it here and then search for a specialist in prototype PCB assembly. That would take too long and defeat the purpose of making a PCB prototype in the first place. Work with assemblepcb, and let us do it all for you – fast.

PCB Prototype Assembly Featuring Our Equivalently High Quality Standards

While prototype assembly typically consists of a limited production run, we bring the same high level of quality and care to the process as with our full-production assembly projects. We utilize the same resources and personnel to ensure the best possible results. Our capable team is fully qualified to handle every aspect of the process, including the procurement of parts and components, circuit boards fabrication, assembly manufacturing and quality control. We will also follow your original prototype design to the letter. We won’t make any modifications or alterations without your approval.

Our services include Design for manufacturability (DFM) and Design for Testing (DFT) to ensure your prototype will meet your exact design specifications. We can even assemble prototypes for high-density FR-4 circuit boards.

You Can Count on Our Fast Project Turnaround Times

Assemblepcb can get your PCB assembly prototype to you in a matter of weeks or days, not months, which allows you can to go into production faster, which means you can and start seeing profits faster. We’re able to promise such completely due to our flexible assembly options, high availability of components and stable and long-standing cooperation with authorized component distributors or manufacturers. If your design isn’t going to work or you need to make adjustments when it comes to the final assembly, you can find out faster than your competitors. You can then have a chance to perfect your design for assembly and have a finished product before your competition gets off the line.

The business world moves extremely fast, especially when it comes to consumer electronics. Often the company that is the first to market gets the lion’s share of the profits. At assemblepcb, we want that company to be you, and with our fast PCB prototype fabrication and PCB prototype assembly services, we know we can make that happen.

Prototype PCB Assembly at Competitive Prices

Assemblepcb offers a number of ways to minimize your PCB prototype assembly costs. We enlist the services of multiple reputable parts suppliers, enabling us to purchase the most affordable parts for your project – while sacrificing nothing in terms of quality. We also offer a number of cost-effective packaging options, as well as highly advanced processes for selecting the one that will save you the most money.

We are the best possible option when it comes to all of your PCB solutions including printed circuit board fabrication, component sourcing and prototype assembly needs. Because we do everything in-house with our team of highly-trained engineers and design experts, you know you’ll get a smooth and efficient flow of communication that will result in you getting just the prototypes you want. You or your management team won’t get tied up in logistics trying to get a design company to communicate with a manufacturer.

To get PCB prototype assembly quote for your custom PCB project, please click the following button and upload your circuit spec and BOM. We will give the PCB Assembly price within 48 hours.

There is really only one company to contact when you have PCB assembly needs, and that’s ORINEW TECHNOLOGY CO.,LIMITED. Check out this list of some of the high-quality PCB assembly services we offer:
• One-Stop Fabrication and Assembly: A turnkey start-to-finish solution meets all your needs.
• Multiple PCB Assembly Services: SMT, THT, Mixed Assembly, Package on Package (POP), Rigid PCBs, Flex PCBs – if there’s a type of printed circuit board that can be assembled, we almost surely do it.
• Flexible Volume Assembly Alternatives: Prototypes, low volume, high volume — we do it all.
• Parts Sourcing: We have years of experience and stable relationships with authorized electronic components manufacturers and distributors, so you always get real, quality parts. All parts go through 100 percent quality inspection before use.
• Comprehensive Quality Assurance: From visual inspection to AOI and X-ray inspection, we take quality control very seriously and test everything rigorously for functionality and quality.
• High Efficiency, Low Cost: You’ll appreciate the value of our added free services, like our Valor DFM/DFA check and expert professional design assistance.
• Professional Engineering Team: We’re highly qualified and dedicated to the success of your project, allowing you to start with optimized designs and giving you a better chance to meet project deadlines.