Quick Turn Prototype PCB Assembly

XDF provide full prototype PCB assembly Services, Send your PCB files and Bom list to Sales@pcba360.com,  Estimate total Cost Now !

There are many names for prototype printed circuit board (PCB) assembly. Other names you will commonly hear are: surface-mount technology (SMT) PCB prototypes, PCBA prototype assembly, PCB sample assembly, etc. The term PCB assembly

refers to a fast prototype PCBA used to test the function of new electronic designs. These help with quality assurance, verifying that there is no problem with the test product, finding bugs, and updating the design. Typically, before mass production, one electronic project will need 2-3 iterations of a SMT assembly to make sure everything is working perfecty. 

XDF supports engineers to assemble their electronic prototype quickly and cost effectively during the whole design verification process. To ensure that the product design meets requirements, in general, we suggest 5 pcb or 10pcs for prototype assembly testing. Of course, one or two piece is also OK, so long as it can be verified.  

Anyone interested in electronics and electronic circuit boards needs to understand the various stages of developing and producing a printed circuit board. It can come in handy when you are seeking a top prototype smt assembly provider. The various production stages of printed circuit boards entail design, prototyping (prototype PCB development and rapid prototyping pcb assembly), and PCB high volume production. Different entities will always seek part of the whole production process depending on their electronic circuit board needs.

However, this article seeks to help you understand everything about prototype PCB assembly, a fundamental aspect of the PCB production process.

Rapid prototyping pcb assembly represents a fundamental phase of the printed circuit production process. It is also inferred as PCBA prototype assembly, SMT or surface-mount technology PCB prototype, PCB sample assembly, etc. From these alternative names, the meaning of prototype assembly regarding printed circuit boards becomes apparent. So what is assembly prototype?

PCB prototype assembly service is a fast prototype printed circuit board assembly primarily used to test fresh or new electronic designs. Consequently, it assists with checking and ensuring quality assurance of the PCB. For instance, it verifies that no bug exists in the test PCB, updates the design, and finds bugs. In most instances, prototype assembly of an electronic project will require two or three iterations to ensure everything is perfect.

If you have developed a printed circuit board design and want top prototype pcb assembly supplier, it becomes prudent to pick a top prototype circuit board assembly company. What better company than XDF PCB and Assembly Company. The company assists engineers and designers in assembling their electronic prototypes at a cost-effective price and quickly. You will get quality prototype pcb assembly supplier because design verification also takes place. However, you have to provide the recommended five to ten pieces for the prototype assembly testing.

Printed Circuit Board Services to Consider when Picking a Top Prototype PCBA Company

• Engineering services on offer, and which relate to the prototype printed circuit board
• Here it would help if you considered whether the company offers DFM or design for manufacturing services. Additionally, it should also provide DFT (design for testing) and DOF (design of experiments). DOE entails value-added engineering services developed control plans.
• Prototype assembly services that the company offers. It would be best to determine whether the PCB assembly company performs single and double-sided surface-mount assembly. It should also have the capacity to perform selective soldering and plated through-hole. Additionally, mixed technologies also help, therefore, consider one that can combine through-hole, electro-mechanical, and SMT assembly.
• Printed circuit board assembly function testing
• Here, it becomes prudent to consider services such as flying probe testing, circuit wire bonding, and in-circuit testing. Additionally, the company should also provide PCBA conformal coat and functional testing.

Prototype Printed Circuit Board Assembly Process Steps

Understanding the PCB prototype assembly process becomes key in estimating the cost and other related aspects before approaching a prototype pcb production company. The assembly process includes the following.

• It represents the first step, and it starts by allocating a distinct 2D barcode for each printed circuit board.  The barcode becomes instrumental in allowing any needed trace-back, and for this to get achieved, the barcode gets scanned throughout the assembly process. Crucial information like supplier details and every component’s delivery documents also get tracked. Further, the process steps deployed, the time, and the person who undertook the process also need to get linked to the PCB specifications and BOM revisions.
• Stenciling of the solder paste. It is the second step of the assembly process and features equipment like a MEDL stencil printer incorporating solder paste on the bare printed circuit board.
• Pick and place. The third step entails placing the SMD components accurately using the pick and place machine.
• It comes after the accurate placement of the components. The inspection ensures that the correct orientation and placement of SMT (surface mount technology) components before relaying the assembly to the soldering stage.
• Reflow soldering. It is the next step in the assembly process, and the printed circuit board gets placed in the reflow oven with every relevant component. The oven often consists of diverse zones, and it ensures the hardening of the solder paste. However, it becomes essential to remember that using a solder paste with a low melting point stands recommended. It entails eliminating the risk of damaging any of the PCB components by the high temperatures accompanying the soldering process.  
• Another round of inspection. It becomes essential to conduct another inspection round post the soldering process of the SMT components. It allows for the detection of any potential defects of solder joints. The inspection often gets completed manually or by a machine, depending on the requirements and specifications of the customer.  
• Insertion of through-hole components. It is the next step after the second round of inspection. Through-hole components get placed manually on the printed circuit board, and thus, you must ensure the correct orientation. The soldering, however, gets carried out by a machine or manually- by hand, though this depends on the extent of the needed selective soldering.  
• Technical edge cutting. It represents the subsequent stage post the insertion of the THT components. Before you start, however, you need to ascertain whether you will deploy automated machines for the assembly process or do it manually. If, for instance, you are using machines, then the printed circuit boards will get equipped with the technical edges, edges that need cutting off after completion of the assembly process. However, when the PCB comes as a panel and possesses numerous single circuits, it becomes imperative to separate the panel at this stage. Clean cutting of the edges requires you to ensure pre-cut V-cuts or break-out tabs early during the ordering process.
• At this stage, when the cutting off of the technical edges has already concluded, the third round of inspection happens. It is an inspection round that intends to verify the orientation and placement of every component to ensure it is all correct.  Additionally, the inspection also ensures that the quality of the solder connections besides the edges proves top-notch.
• It comes as the next step after the last inspection. Here, the prototype PCB assemblies get packed in safe ESD packages. It is crucial to note that each assembly needs its ESD shielding bag. However, when the printed circuit board prototype dimensions surpass the standard packages, then the assemblies get packed in anti-static foam.
• Quality control. The last step before the packages gets closed for shipping entails a round of quality control check. Here a sample gets optically checked to ensure the PCBA prototype is of sound quality.

Estimating the Cost of a Prototype Assembly Project

The ability to accurately predict the cost of your prototype pcb production project can prove a tough ask. However, you can always come up with estimates of the total costs. So how can you go about this? One of the best ways often entails getting a quote from your prototype PCB assembly manufacturer. The requirements, however, prove different with each prototype PCB assembly company. For instance, at XDF PCB and Assembly, you can always get a complete price quotation in two days once you have sent your PCB design file complete with a bill of materials. Further, you will have to enclose specific details such as the BOM list, your Gerber file, and the required prototype PCB quantities.  Additionally, you will also have to specify any need for special technology utilization in the assembly process.

At XDF PCB and Assembly, no MOQ limit exists for prototype printed circuit board assembly. Therefore, you can always order even a single piece of PCB prototype. What’s more? The price of components will get based on the BOM list you send.  However, you can always request equivalent replacements to cut the cost as long as you make an official approval of the request.

The company has a demonstrated history and capacity to handle your prototype PCB assembly needs owing to its qualified workforce that will manage the process. Additionally, XDF PCB and Assembly possesses the latest technologies and equipment to handle your prototype PCB assembly needs ranging from one piece up to a thousand pieces. Hinging their operations on delivering quality PCB prototypes within short turn-around times, picking us will always prove an inspired decision.  

Another crucial aspect of estimating the cost of production depends on the services and PCB product sourcing avenues of the prototype PCB service provider. For instance, if the company has a qualified team of engineers and sources the parts necessary for your PCB design assembly process in-house, then the cost drastically reduces. The opposite also rings true for companies that outsource services or PCB components. Here the price will always rise, and this can hamper your plans with the developed PCB prototype.

Finding a PCB turnkey service provider for your prototype assembly and sources for the diverse components allows you to worry yourself with the design, which saves you money. Additionally, a company such as XDF PCB that sources for components ensure that the components used in the assembly process of the PCB prototype are of top-rate quality owing to the quality certification and standards that it must protect in its operations. With advanced optimal selection criteria for packaging, you also get to reduce the cost, a crucial indicator of the total cost of the prototype smt pcb assembly.        

Another crucial determinant of a prototype PCB assembly service provider is labor charges, parts costs, and bare circuit board pricing or rates. To determine this, all you have to do entails accessing the company’s website, sending your prototype PCB Gerber file, and getting an estimate based on the supplier or assembly service provider.    

Most prototype smt pcb assembly providers guarantee prompt delivery though this often depends on the capacity of the company and the documentation you submit. For instance, the average timeline always comes at two weeks when all factors remain constant. However, for XDF PCB and Assembly, you will only need three days to get your delivery. Consequently, the quality and turn-around delivery times have to figure in your cost estimates, especially based on your budget and application needs.  It becomes crucial to note that we do a thorough evaluation of the engineering concerns and inquiries related to components before stating the PCB assembly process.

Mechanisms of Guaranteeing Top-Rate Prototype Assembly of Printed Circuit Boards

If you want top-quality printed circuit board prototypes, it helps to find the best prototype PCB assembly services provider. To determine the capability of the company to offer quality PCB prototypes for your needs, ascertain the following.

• That the company has ISO 9001 certifications when it comes to quality management systems
• That the company has an X-ray detection system
• That the company performs a 100% printed circuit board assembly testing
• That he company performs an AOI (automatic optical inspections)
• High standards of class two IPC-600G and IPC-6012B
• 94v-0 UL certification level
• The company performs an ICT online test besides the functional test
• That the company uses materials that comply with the RoHS

 

How to Select a Prototype PCB Assembly Service Provider

Picking a top pcb prototype service provider can become difficult owing to the number existing out there. However, to pick a top-rate one based on your PCB prototyping needs, you need to consider the following.

• Firstly, it becomes important to consider the professionalism and capacity of the service provider by determining their management system and equipment. If a prototype PCB assembly services provider is professional, their equipment is likely to be complete and advanced. Additionally, a top company will also possess the ISO 9001 certification regarding quality management systems. Therefore the quality certifications can act as perfect beacons in understanding the expertise of a prototype assembler.
• Secondly, the feeling you get from a prototype PCB assembler will also act as an ideal beacon of understanding their top-level status and ability to produce excellent PCB prototypes. Therefore you need to judge the assembly company based on their service attitude.  For instance, formality becomes crucial in business though a too formal company can represent a challenge in addressing modifications to the design, etc.
• Lastly, the reputation of the company also signifies its ability to assemble quality PCB prototypes.

Conclusion

Prototype assembly acts as an integral part of the printed circuit board manufacturing process. It informs the ease or difficulty of the high volume assembly process regarding a specific PCB design.  Understanding everything you can about prototype pcb manufacturing acts as the ideal springboard for picking the right prototype PCB assembly services provider.