How to do a good job of lead - free assembly electronics

Transitioning to lead-free assembly electronics requires not only product reliability, but also the ability for an optimizedPCB assembly process. Additionally, material selection, component changes, and handling potential testing failures are integral to a successful transition. 

Choosing Materials

Surface finish is one of the key material choices impacting the entire assembly electronics process. The assembly process itself, plus the complexity of the board and its use environment, all make an impact on this decision. Typical options include lead-free HASL or ENIG, OSP, ImAg, and ImSN, with new innovations becoming market-ready all the time. Different laminates are often under-specified due to underestimating their quality during the assembly process. Alternatively, laminates may be over-specified, which commands a higher cost.

Solder alloys are another important decision: wave solder, surface mount, and solder for BGA balls all have to be considered. Typ[ically, SAC305 is the surface-mount alloy of choice, and it performs acceptably under most circumstances. Depending on the complexity required for your wave solder alloys, the most cost effective solution is SnCU, especially if you have thin boards with low-aspect holes that need to be filled. SnAgCuNi is preferable for more challenging holes, although this may depend on the surface finish and choice of flux as well. For board flexing capabilities, or withstanding shock events, a variety of lower modulus alloys like SAC105 are becoming more prevalent.

Component Qualifications and Testing

Early adopters of lead-free assembly electronics discovered frequent occurrences of melted plastic components on wave solder connectors. This lead to a switch away from nylon 66 toward the more appropriate nylon 46, or sometimes LCP. These meet the requirements of moisture and temperature sensitivity, a must-have in surface-mount LF components. 

Other components that need to withstand heat damage may be more difficult to detect, which makes preventing that damage a greater challenge. Electrolytes within electrolytic capacitors may boil if time limits and safety temperatures are exceeded, yet these limits are not always outlined in sufficient detail.

Common specs may offer some suggestions, yet without the necessary variables to predict possible behavior. Component engineers end up guessing at preheat durations and total peak heat, while attempts are made with lead-free alloys to properly fill holes under various conditions.

Testing the strain capability of separate components following lead-free assembly is another blind spot. For example, it’s commonly known that SAC alloys have a reduced tolerance for strain, yet their assembly manufacturing people rarely offer specific limits for these devices. If suppliers could record results of four-point bend testing for their components in order to determine an objective maximum strain capability, the user could know if problems are more likely to arise during component stuffing, performing ICT, or attaching their boards to the chassis.

Reworking

All too often, lead-free reworks are overlooked in favor or meeting tight manufacturing schedules. However, records indicate that reworking is one of the greatest challenges involved with making the transition to lead-free assembly. A Lead-free assembly electronic has a more difficult window lying between the cold solder on one end and heat damage at the other.

Reworking can bring operator-to-operator benefits to the mix, optimizing equipment process that was probably originally designed for Sn-Pb rework. Every critical component requires a strict rework process which must be rigidly adhered to. Extensive failure analysis has to be undertaken before a determination regarding appropriate rework procedure can be made. Damage to the PCB, the component itself, or any neighboring components must be prevented. New rework equipment may be necessary, as well as the employment of new shielding techniques. 

Implement Auditing

Despite the growing experience with assemblage of lead-free PCBs, high quality is not always maintained after high-volume production begins. A comprehensive audit plan should be in place to address with the supplier in order to ensure accountability.  Making the change to lead-free assembly electronics provides an excellent opportunity to review your supplier’s typical process, and make any necessary adjustments for optimum quality control.

Electronic assembly

Electronic assembly stands for the process of soldering components onto printed circuit board by SMT and THT technology, programming to do complete function test so as to get functional PCBA board, making box building of PCBA boards with metal casing, plastic parts and then forming a product for sale. As a professional electronics assembly services provider, NOD Electronics fully offers component procurement and inspection, assembly, test and box building with sophisticated manufacturing solution and engineering process. At same time, some custom requirements could be well supported here with high flexibility.

Electronics Assembly Capabilities

• PCB Manufacturing (up to 12 layers, HDI, buried and blind vias available, down to 3.5mil spacing and line width)
• Component procurement (originally sourcing from manufacturer or general agent)
• SMT Assembly (4 SMT lines, down to 0201 chip, 0.25mm BGA, package of PQFP, PLCC, SOP, SOJ available)
• THT Assembly (2 lines, 95% skillful workers)
• In Circuit Test (custom fixture, supporting complex test plan and massive test points)
• Programming and Function Test (professional environment, temperature/humidity, drop test)
• Burn In test
• Box Building (2 lines)
• Quality Assurance (incoming material quality control, in-process control, outgoing control and in compliance with ISO9001:2008 and IPC-A-610E)
• Quick Turn of Prototype and Mass Production

Electronics Assembly Advantages of NOD Electronics

We've got 7 years experiences of electronics assembly and are serving a range of customers from USA, UK, Netherland etc. Our one-stop manufacturing services from procurement, assembly, test and after-sale will make you comfortable. Our capabilities of sourcing best cost-effective components will make your cost reduction into a reality. The pass rate of PCB assembly is over 99.8%, which will meet your requirements. What's more, we can offer customs clearance and international logistics. In this case, you will enjoy first-class services and wait for products after placing order to us.

Now, let's start to contact NOD Electronics.

China PCB Manufacturer

China is the PCB manufacturing base with 75% shipment of global volume, which benefits from perfect industrial supply chains, manufacturing capabilities and cost performance. As a China PCB manufacturer located in Guangzhou, NOD Electronics keeps long-term relationship with global customers by its leading PCB manufacturing capabilities and services. We strive to be your top choice of PCB manufacturer based in China.

We invested 15 million to build senior PCB manufacturing lines with monthly capabilities of 50,000 square meters. Regarding engineering process, we will take quality and efficiency to serve you. Now we support up to 12 layers, blind and buried via, impedance requirements.

• Max. Layers: 12
• Max. Thickness: 8.0mm
• Min. Thickness: 0.4mm
• Max. Thickness/diameter Ratio: 14:01
• Max. Copper Plating: 10oz
• Thinnest 4 Layer: 0.33mm
• Max. Hole and Pad: 0.15/0.35mm
• Drilling Precision: +/-0.025mm
• PTH Tolerance: +.-0.03mm
• Min. Spacing/Width: 0.065mm
• Surface Finish: ENIG/OSP/ HASL/ Au Plating (soft/hard)/ Immersion Ag/ Immersion Tin/ Bright Tin Plating/Ag Plating/ Carbon Ink
• Quick Prototype: 20 hours
• Quality Inspection: 100% (thorough IPQC, flying probe/test fixture)
• TS16949/UL/CE/RoHS/ISO9001

What's more, we support one-stop component procurement, assembly and box building, and delivery fully functional PCBA boards to your hand. Robust box building capabilities and DFM analysis make us to believe we will become your reliable PCB manufacturer based in China. NOD Electronics fully takes customer experience of great satisfaction on basis of cost reduction.

Now, let's start to contact NOD Electronics.

Contract Electronics Manufacturer must provide you with four kinds of services.

You may be really looking for an electronics manufacturing service provider, and you may be having a headache for how to make a decision. In order to meet your production, you want to increase value-added and reduce costs, in fact, you do not only need these, let's explore what services you should pay attention to.

1. New Production Services

As today's consumers are continuously seeking out electronic devices that can work faster and smarter, electronics companies must work hard to hold their customer's interest by continuously updating their existing products and creating new product lines. Unfortunately, the extensive design and development processes can become very time consuming and stressful. As such, it is not uncommon for creative teams and engineers to become burned out, or become too close to the project to see ways of enhancing the design schematics, creating a more efficient device, or solving problems. By working with professional contract electronic manufacturing services, new sets of eyes are introduced to the project, ensuring that each of your device's plans have been viewed from every possible angle. In this way, you can complete the design process more quickly. From here, your contract manufacturer can help to develop prototypes and move into the actual PCB assembly process. 

2. PCB and Systems Assembly Services

Your contract electronic manufacturing services provider should be well versed in PCB and systems assembly. As you look into working with prospective manufacturing companies, you should find out about the production technology that is utilized by the business in order to ensure that the latest machinery is utilized in assembling your devices for maximum efficiency and effectiveness - regardless of how complex your products are. Amongst other things, he PCB and systems assembly capabilities of your manufacturing company should include:

• Rosin, No Clean, and Aqueous Flux Chemistries
• Multiple Through-hole assembly areas
• BGA X-Ray and Rework
• Automated SMT print inspection
• Automated Optical inspection
• Bonding and underfill
• CT and Functional Test
• Box Build
• Configure to order/build to order
• System assemblage at the Chassis, Cage or Rack level
• Customized cabling
• Board level and system level testing

3. Testing Services

There's nothing more embarrassing and detrimental to the reputation of your electronics business than producing a line of faulty devices that make it to the shelves, only to be recalled. The cost factor for disposing of the bad equipment, redesign, and re-production involved with these types of problems alone can be extremely devastating. In order to catch any issues quickly and prevent major losses, it's imperative that your contract PCB manufacturing services provender is able to provide ICT and Functional test services for virtually everything that it builds. Your manufacturing partner should have the know-how and experience to troubleshoot complex analog, digital, and/or RF products and come up with fast solutions. Any defects that are found during the testing process should be quickly corrected by your manufacturing partner, and captured in a database for both reporting and trend analysis. 

4.  Fulfillment Services

When the production of your devices is completed, the work isn't over for good contract electronic manufacturing services. Your partner should be able to offer flexible, customizable solutions for all phases of your product's life cycle - extending even to direct customer shipping and a repair and return depot. Through quick troubleshooting and corrections, the need for expensive warranty replacements can effectively be eliminated. In this way, you can remove the "middle man", making things smoother and easier for both you and your customers. It's a win for everyone involved. 

Producing a great product at a reasonable price point is very possible. By taking the time to find a contract electronic manufacturing services provider who can meet all four of these criteria, you and your business will thrive.

Are you ready to get started?

Contract electronics manufacturing to create greater value

Contract electronics manufacturing service providers has been constantly improving their own competitiveness, they strive to provide customers more value added products.When looking at costs across the entire lifespan of the product -not just its initial manufacturing- domestic contract electronic manufacturing services deliver a better product, happier customers, and a superior ROI.

Four More Reasons To Consider Reshoring In 2016

1 - Reshoring is going mainstream

What was once a trend largely among smaller businesses looking to get an edge over the competition has expanded to cover more and more major A-list businesses.  Just last year, General Electric brought roughly 1,900 jobs back from China.  And given that GE is well-known for its cost-cutting efforts, they're obviously not doing this solely for PR value.The problems with offshore manufacturing are becoming increasingly well-known and, accordingly, companies are looking for better alternatives.

2 - Better infrastructure and equipment

China may be one of the leaders in overall PCB manufacturing, but America is still tops in innovation and the adoption of new technology.  Most of the factories in use in China were built 10-20 years ago, and haven't seen many updates, at least outside of the biggest names like Foxconn.

In the meantime, US manufacturers are continually investing in new manufacturing techniques, allowing them to offer products that are smaller, faster, or more rugged.  When the market for electronics is so competitive, a company needs to be able to say their products are being made in cutting-edge facilities.

3 - Fully integrated product developmentPCB-Repair-Services3

Modern US contract electronics manufacturing services do far more than simply build products to spec. They can be true partners, working with you every step of the way, from initial concept through multiple prototypes and into the final build.  Testing and even focus-group sessions are also possibilities.

This can vastly accelerate the development of a product, when one company is handling its development throughout the process.   The testing process, in particular, can quickly iron out the problems in a product before release, creating a product that garners great reviews right out of the gate.

4 - In-house technical support

Who could ever be more effective at providing post-sale support than the same facility which designed and manufactured the product?   In-house support services have the benefit of the engineers' own expertise, as well as gaining insight from the testing reports previously generated.

Contract electronics manufacturing services for our production to provide a great convenience, in order to find a reliable processor, we believe that nod electronic is a good choice.

Surface Mount Technology Creates Better Electronics Faster!

If your PCB assembly shop isn't using Surface Mount Technologies (SMT) in their processes, you're potentially losing out in numerous ways. While SMT production isn't a magic bullet, in most cases it creates smaller and more affordable products.

Older manufacturing technologies, usually called "through-hole" circuits, required large circuit boards with holes physically drilled through them. SMT production, on the other hand, uses a two-in-one glue and solder to eliminate the holes and create direct electronic connections.

This means lower prices for you across the board, and more options for your customers!

Five Ways Surface Mount Electronics Are Superior To Through-Hole

1、Smaller components

With SMT manufacturing, the lower limit on component size is only restricted by current miniaturization technology. Current SMT circuits can host components which are only 0.4x.0.2 millimeters, and the next-gen standards are going to cut those numbers down by nearly half again.

This means more features on-board, with smaller device sizes. Given the trend towards making everything handheld, this is critical for creating devices that will resonate with the public.

2、Dual-sided circuit production.

Another reason SMT products are smaller is that it allows for circuits printed on both sides. Traditional through-hole manufacturing could only have components on one side, because the opposite side was reserved for the wiring connections.

Again, this means higher component density and smaller end-user devices.

3、Faster setup.

For various complex reasons involving the programming of robots, it's much faster to set up an SMT assembly line, even for creating multiple variations on the same product. Likewise, all the drilling required for through-hole circuits significantly increases the number of defective products even on a well-tuned assembly line.

This faster setup time pays off in lower costs throughout both production and pre-production. SMT prototypes will be cheaper than through-hole prototypes, which makes it more affordable to create multiple protos before committing to a final design.

4、Less electronic interference

Because SMT production minimizes the number of open wires, this means the resulting products will be more resistant to electronic interference and RF signal effects. In some cases, this may even make it easier to pass any FCC regulations on RF emissions from the devices you create.

Interference is one of the most infuriating problems that can come up with a device, since there's very little an end-user can do about it. Electronics that aren't affected by the local WiFi or wiring environment will be perceived as higher-quality by users.

5、Better damage resistance

Since SMT boards use a combined glue and solder, they're more generally resilient and able to withstand day-to-day use, especially shaking and minor impacts. This makes them perfect for pocket-sized devices that will be put through stress in a given day.

Surface Mount Technology Creates Better Electronics Faster!

If your PCB assembly shop isn't using Surface Mount Technologies (SMT) in their processes, you're potentially losing out in numerous ways. While SMT production isn't a magic bullet, in most cases it creates smaller and more affordable products.

Older manufacturing technologies, usually called "through-hole" circuits, required large circuit boards with holes physically drilled through them. SMT production, on the other hand, uses a two-in-one glue and solder to eliminate the holes and create direct electronic connections.

This means lower prices for you across the board, and more options for your customers!

Five Ways Surface Mount Electronics Are Superior To Through-Hole

1、Smaller components

With SMT manufacturing, the lower limit on component size is only restricted by current miniaturization technology. Current SMT circuits can host components which are only 0.4x.0.2 millimeters, and the next-gen standards are going to cut those numbers down by nearly half again.

This means more features on-board, with smaller device sizes. Given the trend towards making everything handheld, this is critical for creating devices that will resonate with the public.

2、Dual-sided circuit production.

Another reason SMT products are smaller is that it allows for circuits printed on both sides. Traditional through-hole manufacturing could only have components on one side, because the opposite side was reserved for the wiring connections.

Again, this means higher component density and smaller end-user devices.

3、Faster setup.

For various complex reasons involving the programming of robots, it's much faster to set up an SMT assembly line, even for creating multiple variations on the same product. Likewise, all the drilling required for through-hole circuits significantly increases the number of defective products even on a well-tuned assembly line.

This faster setup time pays off in lower costs throughout both production and pre-production. SMT prototypes will be cheaper than through-hole prototypes, which makes it more affordable to create multiple protos before committing to a final design.

4、Less electronic interference

Because SMT production minimizes the number of open wires, this means the resulting products will be more resistant to electronic interference and RF signal effects. In some cases, this may even make it easier to pass any FCC regulations on RF emissions from the devices you create.

Interference is one of the most infuriating problems that can come up with a device, since there's very little an end-user can do about it. Electronics that aren't affected by the local WiFi or wiring environment will be perceived as higher-quality by users.

5、Better damage resistance

Since SMT boards use a combined glue and solder, they're more generally resilient and able to withstand day-to-day use, especially shaking and minor impacts. This makes them perfect for pocket-sized devices that will be put through stress in a given day.