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Top Reasons Why Consignment PCB Assembly is in high demand!

By | Date posted: | Last updated: July 27, 2021
Consignment PCB Assembly

A wide variety of assembly services are in demand these days, each with its own set of advantages. Clients find benefit in consignment, turnkey and hybrid assembly services for a wide variety of reasons. In the turnkey process, for example, the contract manufacturer is accountable for the end-to-end process beginning with PCB material selection and ending with assembly. The process, therefore, takes away every hassle and ensures the client can focus on their core competencies.

In the consignment assembly service, it is the client that is required to provide the material to the contract manufacturer. Emerging companies, particularly choose to begin production of their electronic components under a consignment model. This is on account of several reasons such as the fact that they may have in-house manufacturing resources.

In between turnkey and consignment assembly lies hybrid assembly where the client provides selected material while the contract manufacturer procures the balance.

What are the circumstances under which consignment assembly is preferred?

Consignment PCB Assembly finds favor when as a client you manufacture expensive or exclusive products. In such a scenario it works well for you to provide the parts to the contract manufacturer. It, in turn, ensures that the manufacturing process is cost-effective and also that it isn’t easy to replicate your product.

The rising demand of Consignment PCB Assembly Services

Consignment PCB assembly services are seeing high demand on account of the following benefits that they offer:

Quality Control

Since the client procures or in some cases manufactures the components, quality control is a given. It ensures that the PCBs adhere to a certain quality, which in turn goes a long way in ensuring efficacy of the final product.

This option can also work well for mass production and therefore where large productions runs are a requirement, it works well.

Quick turn Delivery

Quick-go-to-market is a major source of competitive advantage in today’s landscape. With this facility, turnover time reduces significantly, and go-to-market becomes that much easier. This is because you do not have to rely on a long-drawn supply chain, which could let you down.

Cost advantage

The overall PCB manufacturing cost reduce significantly when you go with this option. Importantly, with these services there aren’t any hassles for the contract manufacturer to maintain their own facility.

Complex Parts

Particularly in situations where the parts are complex, niche, or patented, consignment assembly works extremely well. It also is the go-to option where the assemblies need to be customized to the client’s bespoke requirements.

To sum up

Consignment Assembly finds extensive application where:

  • The PCB relies on a specialized component.
  • The company has a patented product and therefore has easy access to components.
  • The components are complex.

In many cases contract manufacturers also offer an in-depth inventory process to ensure that all parts are available prior to PCB assembly. They also offer storage and warehousing facilities so that the products are available for an upcoming project.

Overall, as a client you are absolutely assured of the quality of the PCB as you count on your contract manufacturer to offer you assembly options such as:

  • Surface Mounted Technology (SMT)
  • Plated Through Hole (PTH)
  • Mixed Technology

In addition to that, customers can also avail RoHS 5 and RoHS 6 compliant assemblies or leaded or lead free assembly, single or double-sided mixed technology assemblies and more as per their bespoke needs.

When the customer’s expertise in part manufacturing comes together with the contract manufacturer’s expertise, it becomes a win-win combination. The contract manufacturer works closely with the customer’s in-house supply chain. What you have, in turn, is a formula to go-to-market early.

Particularly in times like these were the COVID-19 is impacting and finding dependable vendors becomes a process that is replete with multiple issues, the advantage of consignment PCB assembly cannot be overstated. There cannot be a better way to alleviate the hassles of the supply chain than to rely on the customer to offer quality parts when they are needed.

Go ahead and give your venture wings with Consignment PCB Assembly. Quality and control come together in this model, like never before!

Mer-Mar Electronics offers end-to-end turnkey PCB assembly and consigned PCB assembly services for turning your ideas into products. Whether you need partial turnkey assembly or full turnkey or consignment turnkey assembly, we’ve got you covered. From small volume prototypes to large volume production runs using semi-automated and fully automated surface mount as well as through-hole technology equipment, you get everything under one umbrella.

Top Essential Techniques and Rules for Circuit Board Assembly Quote!

By | Date posted: | Last updated: July 17, 2021
Circuit Board Assembly Quote

When it comes to the quality and performance of an electronics device, PCB Assembly has an extremely important role to play. Particularly with the increasing trend towards miniaturization, high-density component assembly is a fine art, one that professional contract manufacturers can help you with.

In such a scenario, it is important to be aware of procurement techniques as well as PCB assembly quote rules. Here is a broad overview.

Documents required to get a realistic Circuit Board Assembly quote

First things first, what exactly are the things required to get an accurate and PCB assembly instant quote? There are 4 major documents that are needed. These include:

  • Bare Board Print
  • Assembly Print
  • Bill of Materials
  • Approved Vendor List

Let us look at each of these in some detail:

Bare Board Print

Commonly referred to as a fabrication drawing or fab drawing, this print requires the following information:

  • Outer dimensions
  • Board thickness
  • Material
  • Number of holes
  • Finish
  • Number of layers
  • Solder mask color
  • Silkscreen color
  • Part number

You will also need to provide the design files in an intelligent data format.

Assembly Print

This works as a blueprint for the manufacturer and shows the location of the parts. It needs to include the assembly part number as also any details on any special packaging required.

Bill of Materials

A BOM needs to incorporate the following details:

  • Part Number
  • Description
  • Quantity
  • Approved Vendor List
  • Separate drawings for any custom parts

Pro tip – It is important that any revisions are meticulously tracked while the BOM format remains consistent.

Approved Vendor List

You could have this list as a part of the BOM as there can be several approved manufacturers for each part.

Quote for circuit board assembly

With some PCB assembly companies, it may be easy to get a quick PCB assembly quote with some very basic information. Not just that, the quotation may be very detailed too. The main point here is to figure out whether when you give the Purchase Order and provide the balance information, will the quote remain the same? Your answer is likely to be a NO. What you would have lost in the process, is valuable time besides seeing your budgets go awry.

It is therefore extremely prudent to have all your requirements across in one go. After all, you need is a cost-effective PCB assembly quote without compromise on the quality of circuit board assemblies from an experienced PCB manufacturer. Imagine a scenario where in the absence of complete details from you and in a bid to quote an attractive price, the contract manufacturer goes with a tin-lead surface finish, while in reality the project requires a gold finish. A last-minute increase in price is likely to cost you dearly not only in terms of the increase in costing but also because of precious time lost. Contrast this with a contract manufacturer who insists on specifications at the outset to offer you a realistic quote. A little more time spent right at the beginning will enable you to receive the accurate PCB assembly quotes from all PCB manufacturers on a comparable basis. With all information supplied, you will be able to compare prices on an apple-to-apple basis and take an informed decision. Some of the other best practices to follow include:

  • Ensure that there is a common currency unit across all quotations. In fact, stick to the currency unit you are most familiar with.
  • It will also be best to ensure that the quotation is made as per a common structure and format that allows you to compare supplier quotes.
  • An oft overlooked aspect is also that not enough attention is paid to the supplier’s explanation of the quotation.
  • Analyzing the source of materials for the PCB assembly manufacturer and identifying the non-human factors that affect procurement cost, is also one way of arriving at the actual cost of the supplier.
  • Similarly analyzing the allocation rate of expenses may also make the comparisons easy.

To sum up, a little time spent at the beginning of the process ensures that you do not have to face costly errors at a later date and get budget friendly circuit board assembly quote quote!

Mer-Mar Electronics has become the go-to solution for all kinds of PCB Assembly services and highly appreciated by various industry leaders for quick turnaround time, error-free, and consistent quality for small to large volume services in the USA. With over 40 years of experience in providing solution for high-reliability application in various industry including Medical, Dental, Commercial, Telecommunication, Renewable Energy, and more. All the applications are carefully manufactured with specialized support, reliability testing and certified workmanship.

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Top Tips to keep your PCB assembly instant quote in-line with your budget!

By | Date posted: | Last updated: July 7, 2021
PCB Assembly Instant Quote

There are many aspects that go into successful PCB Assembly. While quality is of utmost importance, what is also extremely important in keeping your product competitive is the PCB assembly quote that you receive. The good news is that there are a lot of controls that can help to keep the price of the PCB assembly under check without compromising the quality.

Let us delve into 6 aspects that can help keep the PCB assembly quote within your budget.

#1 Schematic Design Optimization

There are a host of factors that influence the cost of bare PCBs (Printed Circuit Boards). In order to keep the cost under check, the following elements need to be carefully evaluated:

  • Number of layers – PCB cost increases with the layer count. It is imperative, therefore, to realistically look at your requirement and optimize the number of layers needed. Instead of adding another layer, making the board slightly larger, for example, can accommodate the routing and power planes.
  • Vias – Just like the number of layers, it is important to evaluate the number of vias as well. Typically, the cost increases with the number of vias. Also, smaller vias tend to add to the cost of the PCBs. It is therefore important to assess the number of vias such that they do not impact cost while ensuring the functions are not impacted either.
  • Shape and size – Typically, standard shapes come at a lower price as opposed to special, customized shapes. If you can go with standard shapes, therefore, you are likely to save on costs. In terms of size, however, the smaller the size does not necessarily mean low cost. This is because with the trend towards miniaturization, small PCBs are high on density as well as complexity. Increasing the size as opposed to increasing the number of layers can reduce complexity and costs to some extent.

#2 Effective Bill of Materials

The Bill of Materials, which is a comprehensive list of components and assemblies is a considerable success factor in the success of PCB Assembly. A comprehensive and detailed BOM serves many functions. A complete BOM needs to include essential items for PCBA such as:

  • Part number
  • Manufacturer name
  • Reference designator
  • Quantity
  • Description and more

A BOM that includes obsolete parts can waste valuable time as alternative components need to be looked for. With the assembler having to source parts afresh, it could drive up the price. Ensuring that your Bill of Material is updated and relevant at all times, is therefore crucial in the interest of saving valuable time and cost.

#3 Component Sourcing

Sourcing components at the right price is a very important aspect of keeping your PCB assembly costs under check. Unless you have strong links with component manufacturers, it is prudent to let the assembler handle this task. Typically, assemblers have robust relationships with component manufacturers. Also, on account of the sheer volumes they source they are able to get preferential prices.

#4 Turn Around Time

While quick turnaround times is an important aspect of early go-to-market, it is important to assess how soon do you actually need the deliveries. Typically, the faster you need the deliveries, the higher will be the PCB assembly quote.

#5 Packaging requirements

Packaging requirements also have an implication on PCB costs. From moisture barriers to vacuum sealing, the more customized and intricate packaging that you need, the higher cost to the assembler and therefore higher your PCB Assembly quote.

#6. Shipping/ Handling Costs

Another sizeable component of the cost is the shipping and handling cost. Once again how soon you need deliveries will have an impact on the overall costs. Also, the serviceability of your location has an impact on the costs. Areas that are considered remote typically will cost more in terms of delivery. It is highly recommended, therefore, that all such factors be worked out well in advance at the time of seeking the quote. A professional PCB assembly manufacturer will ensure that there are no last-minute surprises that can make your budget go awry or cost you in terms of delays in time.

A clear understanding of the above factors as also working with a professional PCB Assembler will make sure that you get quality PCBs, on time as also within your budget.

Mer-Mar Electronics is one of the reputed organizations offering high-quality PCB Assembly Services for over 4 decades. We have a team of professional engineers and technicians who will closely collaborate with you to ensure superior quality products are delivered in the quickest time possible. Whether you need prototypes or high-volume PCB assembly, we are your one-stop solution for PCB Assembly.

Top Quality Influencing Factors for SMT Board Assembly

By | Date posted: | Last updated: June 30, 2021
SMT Board Assembly

Surface-mount technology (SMT) electronic segment assembly intends to build electronic components utilizing automated machines that position components on the board’s surface (printed circuit boards, PCB).

SMT and the concerned SMDs, boost up the speed since they get directly placed on the board. Surface mount technology, or SMT, can be seen in all electronic copies we use. Since the elements used in SMT have a size reduction, the use of PCB becomes more beneficial and efficient.

Factors affecting the SMT Board Assembly Quality

The sureness with which SMTs (Surface mount) are mounted on PCBs (Printed Circuit Boards) throughout manufacturing is circumscribed by various elements, including Prototyping and fabrication, Surface mount devices’ design, positioning adaptation of the installation machinery engine, etc.

  • The BOM preparation

    Since the content forms a significant part of SMT PCB Assembly, component effectiveness significantly impacts printed circuit board quality. It is crucial to be aware of the mentioned points:

    • The elements labeling process should comply with the automatic machine design standards.
    • The elements’ attribute complies with the automated design standards and meets the standardization plus measurement accuracy requirements.
    • Soldering process requirements shall be satisfied by the soldering durability in the constituents and the PCB accessory. Before oxidation, the shortest ends and surfaces of the solder and the structure should be carried out. In specific, vacuum packaging should be made available for moisture control detectors and circuitry and located after when used in a storage container.
  • PCB pad manufacturability design

    As per HP statistics, PCB design flaws account for 70% to 80% of production errors. Even if a bit of skew happens during the SMT process for a PCB with the correct pad design, it can be adjusted by the air pressure of the molten material, which is known as proactive placement. Even if the mounting position is exact, soldering imperfections such as element placement transfers and tombstone forms can develop if the PCB circuit structure is incorrect.

    Therefore, designers must observe the following settlements in the SMT bearing design.

    • Symmetry pad – To avoid sliding issues position and tombstone after solder reflow, for the 0805 or lower chip component, bearings at both ends must maintain the size of the symmetrical pad heat dissipation capabilities to maintain a balanced tense surface. This keeps the pad in a stealth mode apart from keeping it safe.
    • Space between bearings – To ensure the exact size of overlap between the end of the component or tin and pad, when the space between the path is unevenly sized, solder defects can arise. The rest dimensions of the gasket must ensure meniscus solder joints after the end of the component.
    • Width Pad should be able to fit its place, respecting all requirements of the pin itself.
    • Don’t place Vias through the hole.
  • Printing using solder paste

    The immediate aim of extrusion manufacturing methods is to solve the incompatible substrate printing amounts (filling amount and solder paste transfer amount). Due to inadequate solder paste printing, 60 percent of the PCB should be used for maintenance once it is properly configured.

  • Solder component quality

    Storage and application go hand to hand in case of component quality associated with the PCB Solder. The paste is generally balanced between 0 and 10 ° C, or per the manufacturer’s needs. For its use, the optimum temperature of the SMT area must be 25 ° C ± 3 ° C, and moisture must be 50% ± 10%. The solder outcome cover must be corrected as per the specifications of the board. Also, the paste needs to be soldered within a certain period so that the board remains intact.

  • Template build

    Stencils are mostly preferred for printing settlements. Solder printing is a necessary factor, and the stencils are responsible for delivering or affecting the appropriateness of the template. So far, there are three methods of making stencils: molten handling, application of high beam laser, and the process of electroplating.

    • The thickness of the stencil plate- The design base must be smooth. The minor lead calculation must determine uniformity and steel plate thickness to ensure the number of solder outcomes and welding efficiency.
    • Aperture Design- The concerned walls of the design have a shining polish and tend to be free of issues. Aspect ratio = aperture width / stencil thickness (for smooth QFP pitch, IC); Area Ratio = Openings / Basic Areas Area Wall Hole (0201, BGA, CSP).
    • Soldering ball processing- Solder ball processing is implemented in the 0603 or above the chip component can effectively avoid the generation of soldering balls after REFLOW.
  • Scraper

    Use a nickel-plated steel scraper, usually 60°. If there are hole parts, the 45° scraper is recommended to increase the TIN on the pieces through the hole.

  • Print Parameter

    Printing parameters generally include certain things like the scraper pace, working thrust, speeding of the seed drop, freshening capacity, and repeating count. Excessive scraper pressure can cause insufficient tin and increase the wear between scraper and stencils, while external pressure causes incomplete solder paste printing.

  • Accuracy of the equipment

    The precision of the printers and their consistency also influence the durability of the printing of circuit board pastes when produced with higher concentrations and timber. Pressure drove solder lead or patchy lead paste if the Board provides proper care or has suitable reinforcement. The PCB mounting should be level and perhaps even to achieve closeness between the design and the Circuit.

Conclusion

Many factors improve SMT soldering, including new statutory, PCB and solder filler efficiency, and PCB layout. Because these elements’ splicing wires’ imperfections are harder to pin down with technological problems, PCB design is the foundation of quality management for installing. As a result, effective inventory performance measurement and outstanding PCB patch design are two advantages of enhancing soldered reliability. We can predict that experts are preparing various surveys to make engineers understand the beneficiary facts of SMT. SMT is undoubtedly going to be the pace of technical aspects and building with a designated period.

Mer-Mar Electronics is an ISO certified company and ITAR (International Traffic in Arms Regulations) compliant manufacturer who deliver the best RoHS Compliant PCB Assembly services for over 4 decades. We have the capabilities to handle single-sided or double-sided, SMT or through-hole. Our consistent quality and quick turnaround time endear itself to our customers, who look at us as a one stop-shop for all their PCB requirements.

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