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Overview on PCB Fabrication Process

Once you assign the best PCB manufacturers in India with a professional and prosperous background, you will avail of the best quality PCB.

The electronics industry has grown rapidly in the twenty-first century, and not knowing about PCB is rare. In our technology-driven world, PCB has been a game-changer for a decade. The PCB design and production process are essential for anyone in the electronics industry as PCBs are the base for almost all electronic circuits in this era. 

PCB manufacturing process involves design steps that are crucial for efficient PCB mass production, with minimum risk of troubleshooting and optimum design quality. 

This article will walk you through the overall PCB manufacturing process and its implications. So, if you want to understand more about it, continue reading further.

Synopsis of PCB Fabrication

PCB is an essential component of every electronic device, and thus, PCB manufacturing companies in India would require extensive knowledge about the PCB fabrication process. There are three types of PCBs in the market – multi-layered, double, and single. All three of them have the same production.

From graphic plating to creating the board layout, from drilling to silk-screening, each step of PCB production requires supervision. Precise PCB fabrication is necessary to ensure the proper operation of an electronic device.

PCB Manufacturing Process

Fabrication is a critical component of any printed circuit board. It is followed by a series of inherent steps such as PCB design, lamination, drying, etching, etc. However, it is necessary to have a good understanding of PCB manufacturing concepts before moving on to the direct fabrication part.

PCB Design

The design of the PCB is the first step in the PCB manufacturing process. Using design software, the designer creates the initial schematic of the PCB, outlining all the requirements. It reflects exactly how the board will operate and the placement of all components. PCB design is then sent to a PCB fabrication house to create the PCB. Once all the checks are done, the PCB design is ready for printing. 

PCB manufacturing

The next-in-line step is the manufacturing of the printed circuit board. This step entails two vital steps. The first step is the PCB fabrication, wherein the circuit board is created, while the second step entails the printed circuit board assembly process. 

PCB assessment

After you've completed the preceding steps, it's time to assess and finalize the PCB's performance. During this step of PCB analysis, it is decided whether the PCB design is excellent or requires any specific improvements. If it needs any changes – the design team and the developer would do the needful. 

Printed Circuit Board Analysis

The final step in the PCB fabrication process is the PCB assembly process. The mount particles are soldered onto the empty board during this process.

Understanding Printed circuit board fabrication is essential as it is not only about design. It is vital to check and ensure profit rate, dependability, and manufacturing ability. Without comprehensive knowledge of PCB fabrication, it is impossible to make decisions about the layout, material, paths, limitations, and so on during the process.

Thus, it is significant to understand the procedure of PCB fabrication. 

The significance of selecting the best PCB manufacturer

Finally, note that PCB fabrication is a complex process. As a result, it necessitates the appropriate level of expertise, accuracy, and proficiency. If you run into problems while fabricating your PCBs, ensure to contact an experienced and skilled PCB contract manufacturer. 

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Know how SMT assembly helps you reduce production cost

Surface Mount Technology (SMT) assembly has managed to build a strong place because of its performance efficiency when it comes to the electronics manufacturing technology. The OEMs (Original Equipment Manufacturers) also have to consider reduction in the cost along with ensuring high reliability.

There are series of steps that are followed while carrying out the SMT assembly which in turn guarantees the best quality in the final products delivered. It is difficult to go for any changes after the final stage, and if any changes are needed at any stage of manufacturing will definitely increase the cost. So it is highly advisable to under the SMT assembly  processing depth before it starts, this is neither affect the performance nor will tend to increase the cost.

So study the steps involved in SMT assembly in length & reduce the cost of production. Below mentioned are the steps carried out for SMT assembly:

1. Solder Paste Printing

The foremost step here is solder paste printing wherein a required amount of solder paste is placed on a pad. The components are then soldered on this pad only. Taking in view three main points the quality of solder paste printing is determined- scraping speed, solder paste condition & scraping angle.

The storage of the solder paste should be done in a right manner. Even the application of the solder paste should be proper, then only one can secure a high quality by SMT assembled PCBs. It is advisable to store the solder paste at a low temperature in the fridge, & before application on SMT manufacturing line, the paste should be bought to room temperature level. And, the remaining solder paste should be utilised within two hours. Other important part is to set the solder paste parameters, like the speed & the scraping angle, these two are very related especially with the leftover amount on the pad.

2. Solder Paste Inspection

This step is completely optional but if done is quite beneficial &in a way also helps in reducing the cost. And, it always better to rectify the errors at an early stage. SPI will help to give better products with assured quality & lesser incurred manufacturing costs. Majorly, the defects are occurred at the solder paste printing stage only, so if the inspection is done at the earlier stage only, there will be less defects found in the later stages, or even no defects may be found. One can choose from two different types of SPI: 2D & 3D.

3. Chip Mounting

This is one of the important step in the SMT assembly process. The chip mounters are different from each other initially when compared keeping in mind mounting capability & speed, & the chip mounting stage is completed by these chip mounters only. Bigger components for e.g. connectors, ICs, & BGAs are placed with the help of multi-function chip mounters, these are generally low in speed. Whereas, the smaller one are placed by chip mounters that are of high speed. This helps the components to get printed on the solder paste on the circuit pad.

Alignment is must for the components as the process of alignment is time-consuming & so the speed for multi-function chip mounter is low in comparison to the high-speed chip mounter. 

4. Place Components by Hand & Inspection

Once the chip mounting is done, compulsorily conduct a visual inspection, so that you can ensure zero defects in the reflow soldering. You can come across issues like missing some parts, misplacement & more. And once the reflow soldering is conducted, it becomes difficult to rectify these errors, as in the reflow process the soldering paste gets more solid onto PCB. This will rise the production cost& reliability decreases.

One can also place the components with hands directly, these components can be DIP components, large components or the components which were unable to be placed through the chip mounters. 

5. Reflow Soldering Process 

This is the process where the solder paste is first melted in order to achieve IMC which is needed to connect the board and the component pins. There are certain steps of temperature setting in this process which starts with preheating, rise in temperature, reflow & cooling down. Try to maintain the temperature in the required range suiting to the capability of the components. So the process of setting the temperature decides the cost of the production & also helps in improving the quality. So always search for an experienced manufacturer who knows the factors influencing the quality of the soldering. This all efforts will help in reducing the production costs. 

6. Automated Optical Inspection

After the reflow soldering the components get fixed on the PCB & an important part of SMT assembly is accomplished. But before using as final products, these assembled boards have to be inspected & tested. And this performance test & inspection is done with the help of Automated Optical Inspection (AOI), this application will help in detecting defects like edge on, tombstone, misplacement, missing components, bridging, orientation & empty solder.

7. Automated X-ray Inspection

This inspection is the upgraded version of the AOI, as it helps in detecting more direct & clear defects. This step is not necessary one, but to achieve a good product quality & low cost, this inspection machine will help in achieving those relevant steps. 

8.  Function Test or ICT

The ICT helps in testing whether there are any shorts & opens in the circuit & also exposes defects of the components by measuring the inductance, resistance & capacitance. This will help in higher performance of the components once the reflow soldering is done.

Whereas the Function Test not only helps in testing the shorts & opens of the circuit board but also tests all the functions performed by the assembled PCBs, this is important, as this test will help in achieving greater level of performance.

So following a step by step SMT assembly process will not only help in reducing the production cost but also increase the reliability & performance of the final products. So the PCB manufacturers hould be aware about these basic steps to be followed in order to achieve higher productivity with lower costs.

To get more information about Surface Mount Technology (SMT) assembly , please visit Jayshree Instruments by clicking on the given link, or visit us directly by following the given contact details,

Contact Details :

Jayshree Instruments 61/D, Omkar Bhavan, Madalpur, Ellisbridge, Ahmedabad, Gujarat 380006 +91-8460959733

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Don't miss out on these considerations for your Cable Assembly

The group of cables are joined together into a single unit for a single purpose, this process is known as cable assembly.This is also known as wiring looms or cable harness.

In order to make the installation quick & easy, these cables are joined very precisely as per the needed orientation & length. This mainly includes different constructing cables & the different colours, lengths & sizes as per the application. So the main advantage of the cable assembly is to simplify the system of connecting & disconnecting or fasten the replacement or repair process.

But, on the other side, there are factors a needs to consider while designing it. Not only the components used are considered but also the production & designing factors are considered to make it more cost-effective & improve the integrity of the system overall.

The usage of cable assemblies is widely done when the production is huge as it helps to save time during the assembly of the equipment or machine & it is more beneficial when it is used for each of the manufactured unit on repetitive basis. For example, the harnesses or the cable assemblies used in the automobile industry.

Let’s take a broader view of the factors that should be considered while designing the cable assembly.

·         Safety

·         Performance

·         Special materials

·         Fit, Form & Function

·         Durability

·         Types of Connectors 

1.      Safety

The custom cables which are to be used should mostly comply with the safety rules & regulations. It is also important to let the manufacturer or designer know about the special needs at the design stage itself, so all the necessary standards are met. It is also must for the cable manufacturer to convey the processes to make sure the final products satisfying the required standards.

2.      Performance

The cable assembly design should be definitely a performance oriented one. The ones with stiff & rigged designs of the contacts not only maintain the performance but also helps to achieve a higher performance under difficult environment also. The industries need to identify the designs of these cable assemblies with care to make the electronic device smaller, lighter & sturdy to perform more effectively. Also, many requirements are needed which includes the speed of the signal, grounding, voltage & the total number of contacts, etc.

3.      Special Materials

As per the needs & requirements the cable assemblies are manufactured using special materials. For instance, the industrial applications used the connectivity components made up of the plastic as this material meets the standards of UL flammability. Whereas, the medical equipment may use polymers to meet the requirements of USP Class VI helpful for biological reactivity. So it is must to use special materials to meet the standards & the requirements of the sectors, this helps a lot in cable assembly process.

4.      Fit, Form & Function

Make sure the that the cable assembly is connected & installed very securely & can be used immediately & even it should also be very easy to combine. Features like polarization, keying mechanism & terminal position assurance can be much helpful in this. This function of being form, fit & function can help in easily making or breaking the design of the product.

5.      Durability

Many factors relating to the environmental conditions also affect the manufacturing of the cable assembly process. So it is must to check the durability of the final product taking into point all the environmental factors to know the failure or success rate of the product. Problems like heat, moisture, cold which are most obvious should also be taken into consideration. Like for instance, any cables used for medical purposes have additional needs so that they are ensured about the sterilization use with multiple patients. So like this all the factors needs to considered the capacity of handling the vibration & shock, handling is rough or extreme level of temperatures, this will help in keeping the durability high.

6.      Types of Connectors

There are mainly two types of connectors used for your cable designing, overmolded & assembled. The difference is that the former is less expensive than the latter & the moulded connectors has more durability than the assembled one. But as everything has two phases, good or bad, same goes with these connectors also. So the engineering team of the cable manufacturer uses the right one for your application.

So it is advisable to communicate all the relevant details in length with your cable assembly manufacturer at the earliest. This small effort will enable the process of designing to be carried out smoothly & effectively and also will also increase the credibility of the manufacturer as he/she will meet the needs of the equipment. And, this will also help in saving the time & be much more cost effective in the short & long run. Hence, make a point in going in depth of the designing process & consider all the above factors during the cable assembly process.

If you are looking for cable assembly manufacturers in India , then visit Jayshree Instruments, They a full range of cable and wire-loom assembly services.Contact Details Given following,

Contact Details :

Jayshree Instruments 61/D, Omkar Bhavan, Madalpur, Ellisbridge, Ahmedabad, Gujarat 380006 +91-8460959733

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PCB assembly for dummies: A step by step guide to getting PCB assembly right

Before many years, food, shelter & water were the essential part for an individual in their day to day lives, but now one major factor is added that is electronics. Our day starts with electronic components and ends with the same, from our phones to our cars to our home appliances. And the most essential part of these electronics is the printed circuit board (PCB).

What is PCB?

So you may have come across the small green chips may be in your phone, or say TV remote covered with copper parts and lines, these tiny green coloured chips are PCB, & they form the heart of that particular electronic device.

The output of the green colour:

The PCB comprises of copper lines, fiberglass, and other metal parts, and these boards are joined together with epoxy and insulated with a solder mask. And from this solder mask, the green colour comes from.

You may have also observed these boards with components firmly stuck on it and for an advanced PCB to work efficiently, the components should be perfectly mounted on it. And a PCB with organised components on it is called an assembled PCB. And the process of manufacturing is called PCB assembly or PCBA.

Do you have any idea about how these devices are made? The process of PCB assembly is an easy one but has many manual and automated steps. Every step, the manufacturer has an option to select from an automated and manual process. Yeah, this is quite confusing, to let’s make this easier and have a look at the below steps from the initial stage to the end with a brief explanation.

The PCBA Process steps:

1. Solder Paste Stencilling

So the processing of the PCB assembly starts with applying a solder paste to the board. It’s similar to the process of screen printing, wherein a thin stainless steel layer of the stencil is placed over the PCB. The assemblers apply the solder paste only to fixed parts of the future PCB, &only the components will be placed when the PCB is completed.

So the solder paste is to be applied evenly on the circuit board, and also in the intended locations where it should be needed.

2. Pick and Place

Once you have applied the solder paste to the PCB board, the process of PCBA is taken to a further step and that is the pick and place one. The PCB board is picked with a vacuum grip and placed on a machine and a surface mount components or SMDs are applied on the prepared PCB with the help of a robotic device. And in the later stage, these SMDs are soldered on the surface board.

Before the invention of machines, this step was manually done with the help of tweezers, & here the assemblers had to pick and place all the components with hands. But thanks to the machines, to make them work for the humans quite simpler and easy.

3. Reflow Soldering

Now when the solder paste and SMD have been placed, they also have to be solidified, to keep the paste and components to remain in their place. And the PCB assembly is skilled through a process called “reflow”.

After the completion of the Pick & Place process, the PCB board is shifted to a conveyor belt. The belt takes the PCB board to a large reflow oven, the oven has many inbuilt heaters & these heaters in turn heats the board to the temperature to around 250 degrees Celsius. The solder is melted into the solder paste with the immense heat in the oven.

As the solder starts to melt, the PCB moves through the oven and is passed through coolers, and this cools the melted solder and solidifies in a controlled manner. And in the end the SMDs are connected to the PCB with the creation of a permanent solder joint.

4. Inspection and Quality Control

Once the reflow process is done, we need to check the quality and conduct an inspection, and at this time the mount components are already soldered into a place. This assembled board is inspected for knowing the functionality.

Manual checks: This is done by an assigned designer, who visually ensures the quality and functionality of a PCB.

Though you come across any mistake or not, you need to carry on the next step that is to check the part and ensure the working of the same as required it to be. This means you have to check the PCB connections for quality purposes. You can carry out these inspections on regular basis to have an error-free working of the board.

5. Through-Hole Component Insertion

Once we pass the inspection stage, the board may add on more components apart from the SMDs, and this includes the plated through-hole components or can be said PTH components.

To explain PTH, it can be said that it is simply a hole in the PCB which is fully plated through the board. Now through these holes, PCB components pass the signal from one side to the other side of the board. And the soldering paste will be not the preferred one, in this case, instead, we need a step higher soldering method for the PTHs. There are mainly two main soldering methods:

Manual Soldering: This is completely manual, through-hole insertion

Wave Soldering: This can be said to be the machinery form of soldering, but with a little different process. Here the PTH component is put in place and the board on the other conveyor belt. The waves of the molten solder are washed from the downwards side of the board at a stroke, and this process is undertaken with the help of the oven specially meant for this process.

6. Final Inspection and Functional Test

The last step is the final inspection which tests the PCB regarding its functioning. This is known as the “functional test”. How the PCB is operated in normal situation is tested here by putting the PCB going through many paces. Simulated signals & power pass through the PCB during the test and the electrical characteristics of the PCB are tested.

If any problem faced in the current or signal output, voltage, or any unacceptable fluctuation occurs, then the PCB fails the test. This failed PCB can be later recycled or whatever are the company laws.

But testing is one of the step not to be missed in the PCB assembly process,as the pros and cons is decided in this stage only.

So widely choose your PCBA manufacturer like Jayshree Instruments that delivers the best services and assuring PCB assembly process meets the high quality standards and work. Contact details given following,

Contact Details :

Jayshree Instruments 61/D, Omkar Bhavan, Madalpur, Ellisbridge, Ahmedabad, Gujarat 380006 +91-8460959733

To get more idea about PCB Assembly Cost, please read the article attached here : Ways to reduce the PCB assembly cost

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Ways to reduce the PCB Assembly Cost

When was the last time you bought something new like shoes or say gadgets or any new thing? And, before buying did you compare the price of the shoes or gadget you want with several other sellers or online sites? And, the answer for 90% for us would be a YES, because it’s a human tendency, to compare prices in different places so that we can even be able to save a small penny from our pocket.

And so does a PCB engineer before finalizing a PCB Assembly Project. So whether the order is small or a huge one, it is advisable to follow certain tips which will not hamper the quality but at the same time help in saving some good costs. This means the PCB engineer has to examine each project and the design of the PCB, to better know where the cost can be saved, where there is an unnecessary usage of costs, & if he/she finds something, this can be changed taking into consideration the functionality of the project.

So the procurement departments of each organization help in the same by following some simple advisory tips & reduces the cost while making the purchases. So let’s check some of the most followed steps which every PCB assembly company in India should follow, which can help in saving huge funds for the company.

There are three important tips to be followed as listed below:

1.      Indulge into multiple sourcing instead of single-sourcing;

2.      The Panelization should be quite flexible considering the manufacturer’s needs;

3.      Form Committees for Multiple Cost Reduction;

1. Indulge into multiple sourcing instead of single - sourcing

Multiple sourcing is always a better option than single sourcing. This is because it will help you in comparing the cost that is offered by the different sources. Along with costs, you can also compare the quality & functionality of one source with another.

So multiple sourcing itself has many advantages apart from only cost reduction. Sometimes, it might also happen, that in case of large orders, a particular supplier might not be able to provide a huge quantity, so here you can contact the other supplier offering the same quality. So have a perfect study of the Bill of Materials and check the components which are costly and check the alternate vendors for them.

And with single sourcing, there is one greater issue that you are dependent on only one supplier & sometimes in the case of huge orders, the lead times play an important role here.

So it is highly recommendable to always opt for multiple sourcing.

2. The Panelization should be quite flexible considering the manufacturer’s needs

The second most important tip in the PCB Assembly processis to maintain flexibility in panelization. So don’t just stick to the original designs because that can after sometimes lead to higher cost & variation can lead to optimization of cost as per the needs of the PCB manufacturer.

With this, you also can look at the design choices like the buried vias & the blind vias, board materials, vias on pads, and many other things that need to be considered. For example, if you think that if you remove vias on pads this can save your cost in a big way, then you can go with that choice of design.

So it is also a great tip to keep the panelization as per the needs of the manufacturer.

3. Form Committees for Multiple Cost Reduction

Which option is considered as more reliable: a) In a clinic, a doctor playing the role of being a doctor, receptionist & a nurse also; or b) In a clinic, a doctor just playing his own role with appointing a nurse & a receptionist to take appointment; And as per the sources, it is always advisable to have a separate allocation of work for each department, so that he/she can focus fully on his/her particular work only, rather than diverting his/her mind in all the other work also.

And this is what the PCB manufacturer also needs to follow. There should be a separate committee for each work like engineering, designing & purchasing, which in turn, helps in concentrating on their own work & reducing the cost and improving the work efficiency.

The work of this Cost Reduction Committee will be to search for opportunities that lead to cost reduction, search for strong components that indicate the avoiding for single sourcing. One more important step this committee can undertake is to balance the order volume, that is, to exactly know how much is the order volume, the more the order volume, the more reduction you can try to get in the cost.

So study the requirements of the organization & then make a consolidated report of the orders & place the order.

So, the above-listed tips are some of the important ones which if followed, can surely lead to a significant reduction in costs in the process of PCB Assembly. Though, there are many other small things which if followed can also lead to a little bit of saving. For example, we have our misconceptions & one myth which comes across the PCB Assembly Processis to have many drill holes on the board materials & this can reduce the cost, but this is completely wrong, the more the drill hole, the more will be the cost, because more holes which in turn, increase the time of tooling. So, proper knowledge of these small factors is also a must in the assembly of the PCB.

With this you also have to focus on the areas in terms of the design, like the below ones:

· Always go for one or two layers;

· If possible, always allow X—outs;

· It is advisable to manage & place the fiducials on the copper layer of the board;

· And, use V-scoring for routing, because the routing helps the excess material to leave on the board;

And when we talk about design, make sure you pass the information accurately & the below points should be covered:

· The documents relating to the design are sufficient & accurate;

·  And along with the specification also mention the fabrication notes on the drawings;

·  Indicate the specifications of the material used;

·  And, last one is to know your parameters clearly like the distance between the traces or so on;

Following the whole of the above process, will be surely a win-win situation for any PCB manufacturer as this helps in cost reduction. But make a note, that cost reduction doesn’t mean decreasing the quality, this should remain intact always. So follow the smart & easy way for delivering an efficient PCB Assembly Services.

To get best PCB Assembly Services near you in Ahmedadabad, please visit Jayshree Instruments. Contact details given following :

Contact Details :

Jayshree Instruments 61/D, Omkar Bhavan, Madalpur, Ellisbridge, Ahmedabad, Gujarat 380006 +91-8460959733

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