In terms of electronic products' function implementations, nothing plays a more significant role than PCB (printed circuit board) that is regarded as the brain of electronics. PCB board tells electricity where to run and how electronic components should be connected with circuit board and other parts working inside electronic products.
Although constant progress of modern technology leads circuit boards to become gradually shrinking, the small size of circuit board never stops it from being multi-functional or highly reliable. As a result, PCB service still covers a wide range of elements each of which directly or indirectly determines PCB board's smooth or successful running.
As one of the most active economies around the world, China without any doubt carries tremendous advantages in terms of electronics manufacturing due to rich natural and human resources, positive national policies, stable political environment and increasingly uprising international influence. Nevertheless, this eastern country with a long ancient history seems a little distinct from what people have been imagining, from which misunderstanding usually derives. Therefore, it's necessary for global customers to learn more about "Chinese characteristics" on China PCB service so that they can make better use of China's resources contributing to high-quality electronics manufacturing for essential benefit achievement depending on electronic products.
In spite of its small size, PCB board still involves so many aspects or even far more aspects than before due to its uprising complexities. Leading elements concerning PCB service include:
• PCB Design
PCB service starts with an idea that is expressed through PCB design file. Circuit board design file in detail tells PCB manufacturers what the PCB will be like after it is generated. Fundamental parameters should be contained in PCB design file such as layer count, copper weight, interconnection on board, silkscreen, solder mask etc.
• PCB Prototyping
PCB prototype is a direct way to test whether a PCB design file goes correct or not and becomes essentially efficient reference prior to mass-volume production. As far as prototype PCB is concerned, lead time and quality is the most significant factor for PCB service and the former is even the more important. As long as prototype PCB is approved, the authentic PCB manufacturing will be able to take off.
• PCB Fabrication
PCB fabrication accounts for the core part in PCB service, laying a solid foundation for electronic connection. PCB is fabricated by conforming to a professional PCB manufacturing process containing a series of steps which need to be upgraded to be compatible with constantly improving market requirement.
• PCB Assembly
PCB assembly comes right after PCB fabrication with components sourcing simultaneously implemented. PCB assembly further expands connection range of PCB board with components participating in PCB service. Up to now, the prevalent PCB assembly type is SMT (surface mount technology) assembly that is an automatic manufacturing line with high assembly efficiency.
• PCB Rework and Repair
PCB rework is a little section of PCB service. After all, high-quality PCBs don't need to be reworked or repaired.
• PCB Sourcing
PCB sourcing features a wide definition in PCB service, covering substrate material sourcing, copper foil sourcing and components sourcing etc. Moreover, it is a direct way to connect manufacturers and customers.
Making better use of China PCB service is like opening Pandora's Box. China not only carries tremendous advantages in terms of electronics manufacturing, but also conforms to positive trade policies around the world. The following steps bring you forward to China PCB service with ease.
Step#1: Convert an idea into a PCB design file.
As long as your idea is converted into a PCB design file, your creativity plane begins to parachute. PCB service is rooted in rational PCB design. To make your PCB design files free from risks that possibly arouse misunderstanding between two counterparts, you (customers) and PCB manufacturers, it's better to provide your CAD (computer-aided design) file instead of Gerber extended file alone because different versions of Gerber file readers possibly lead to information missing or errors.
Step#2: Select a trust-worthy China PCB manufacturer or assembler.
Lots of methods are available to evaluate a PCB manufacturer or a PCB assembler. I believe this step is the toughest among all the steps to obtain China PCB service because there are too many PCB manufacturers in China together with fabless PCB brokers. Once you've picked up a reliable PCB manufacturer, you've made your PCB service half done.
Step#3: Submit PCB prototype or PCB assembly prototype order.
Your PCB design file is in your left hand while a reliable China PCB manufacturer or assembler is in your right hand. Now it's time to get your PCB service ball rolling. After you send your PCB design file to your contract manufacturer, a quotation result will be supplied to you based on circuit complexities and level of your requirement.
Step#4: Confirm quality and performance of prototypes.
When it comes to first-time design and order, it's best to inspect the correctness and smooth running of your circuit design through prototypes prior to volume production. As for PCB service of reorder, it's unnecessary to carry out prototype service. If any modification takes place on your PCB design, however, PCB prototype is still a must-have activity.
Step#5: Submit mass-volume order.
Once no errors are found on your PCB prototypes, your mass-volume production can be sparked. In accordance with your cooperative PCB manufacturer's service habit and level, you either submit online order or order. Of course, the former type is more efficient when it comes to PCB service online.
Step#6: Modify PCB design file to be compatible with mass-volume manufacturing requirement.
PCB manufacturing is so complicated that it covers so many aspects. Moreover, PCB prototyping is after all different from standard PCB so some modifications will possibly be made for mass-volume manufacturing for the considerations of quality and manufacturability etc.
Step#7: Confirm final design file and start mass-volume production.
As soon as your PCB design file is confirmed, your mass-volume PCB production will be instantly started. Up to now, you have completed majority of task in your PCB service.
Step#8: Wait for your products to arrive and win benefits from your finished electronics products.
During the process of order submission, you should pay for your order and select optimal delivery method with a balance between speed and cost. As far as China PCB manufacturers are concerned, the most commonly-used delivery method is through express due to PCB's small size and customers' speed requirement.
It should be acknowledged that obtaining PCB service from China is not perfect, of course. Extremely low cost always attracts customers to fall into some "traps". As a matter of fact, the traps can be totally escaped if you focus on more qualification issues of China PCB manufacturers or assemblers:
Tip#1:China PCB manufacturers are more reliable when they are certified by ISO, UL or RoHS etc. concerning manufacturing technology or quality.
Tip#2: China PCB manufacturers are more reliable when they have their own factory and welcome you to pay a visit there.
Tip#3: China PCB manufacturers are more reliable when they provide you constant follow-up service.
Tip#4: China PCB manufacturers are more reliable when they have been established for quite a long time.
Such tips to optimal PCB service acquisition from China are also available at a large number and each customer sticks to his own evaluation criterion based on which perfect PCB service will be obtained in the end.
In electronics manufacturing, the industrial grade means high reliability and high quality. Suppose your project aims for middle or high-end applications, even though it is a consumer electronics device. In that case, you can require its PCB (printed circuit board) manufacturing to be industrial-grade from the PCB manufacturer.
In this article, you can learn about the industrial PCB manufacturing standards, the key points that determine whether the industrial PCB project succeeds or not, and 4 industrial-grade PCB project examples manufactured by the industrial PCB manufacturer PCBONLNE.
In this article:
Part 1. Industrial PCB and Its Manufacturing Standards Part 2. Industrial PCB Materials and Manufacturing Part 3. Key Points in Industrial PCB Projects: BGA soldering Part 4. Industrial PCB Project 4 Examples Part 5. One-Stop Industrial PCB manufacturerPrinted circuit boards are custom-designed and used for carrying components providing electrical connections and mechanical support. For industrial and other high-current applications, the PCB also assists the thermal dissipation of the system through the PCB substrate.
The features of industrial PCBs include:
On an industrial PCB PCB, the components should be industrial-grade ones. That means, the components on the industrial PCB should meet the below specification standards:
Now, you've learned the components requirements mounted on the industrial PCBs. Let's go back to the industrial PCB board itself.
Are there any standards for industrial PCBs?
Yes.
An industrial PCB manufacturer should meet the following quality standards:
Besides, industrial PCB assembly should also provide high-reliability soldering strength. Industrial PCB assembly should meet the IPC-A-610 Class acceptance standards, which means the PCB assembly process must follow all the IPC criteria.
Except for the different standards and details, industrial PCBs have no differences from PCBs used for the other fields, including the PCB materials and manufacturing steps.
Industrial PCBs usually need to dissipate heat quickly so the PCB materials can be:
High-Tg FR4: FR4 materials are glass fiber of the flame retardant level 4. It is a cost-effective and common PCB material. FR4 materials of high Tg means the FR4 PCB can withstand the highest working temperature of 135°C and above.
Metal core (aluminum and copper): Metal-core PCBs use aluminum or copper as the substrate that can dissipate heat quickly. The aluminum PCBs are usually single-layered or double-layered. Copper-based PCBs can be 1 to 8-layered. This is because it can use the copper bumps to directly transfer heat from the components while separating the electrical network.
Ceramic (aluminum nitride and aluminum oxide): Aluminum nitride PCBs and aluminum oxide PCBs are both ceramic PCBs. Ceramics are insulation materials with excellent thermal dissipation and resistance. They can be used for industrial applications such as COB LEDs, IGBTs, patching beverage can lids, etc.
Qingjian Electronics Product Page
Industrial PCB manufacturing usually includes the following steps:
Cut laminate: Cutting and filleting the laminates to be the PNL (panelization) board's size.
Generating inner layer circuits: Patching a circuit-graphic film above the laminate, going through exposure and development to create the inner layer circuits, and etching to form the circuit lines and PCB pads. Having an AOI (automated optical inspection) for each circuit layer.
Lamination: Going through the browning reaction, riveting, stacking layers, laminating the inner layers, drilling the fiducial points, and profiling the PNL board. It makes the PCB core.
Drilling PTH holes and plating: Using drills to mechanically drill the through holes, going through the electroless plating copper process, and plating a copper layer on the hole walls.
Generating outer layer circuits: Patching a dry film above the PCB core, going through the exposure and development process, secondary copper plating, tin plating, removing the dry film, and etching away the non-circuit-area copper to create the outer layer circuits.
Applying solder mask and silk screen: Using the silkscreen method to print the PCB inks on the PCB and bake them.
Applying surface finish: Using various methods to apply the required surface finish on the PCB pads to protect the copper pads for SMT assembly.
Profiling: Routing the PNL board to the required dimension and size.
Testing and final quality control: Having the electrical connection test, flying probe test, and final quality assurance inspections.
After the PCB manufacturing, the PCB boards and components are soldered through the SMT and PTH assembly to make the industrial semi-products. After box-build assembly, they are installed with enclosures and become the final products or systems.
The devil is in the details.
For industrial PCB projects, one key point is BGA soldering.
The bubble rate of soldering the BGA must be below 10% and should be as small as possible.
The industrial PCB manufacturer PCBONLINE can control the bubble rate of 3% in soldering the BGA.
Let's explore BGA soldering below.
A BGA is a common FPGA chip package type. Its solder balls are in a high-density grid shape and are connected to the bottom of the chip package.
It can provide more functional input and output pins and can be used in high-power industrial applications.
Why are there the bubbles in BGA soldering?
During SMT assembly, after the solder paste hot-melting and solidifies on the BGA pad, a certain proportion of bubbles will occur.
The bubbles will reduce the mechanical strength of the solder joint, can lead to short circuits, and affect electrical connections.
According to IPC standards, any solder ball voids bigger than 25% at the BGA pad inspection area are considered defects.
For industrial PCBs, when the bubble rate is more than 10%, it may affect the reliability and performance of the BGA and the entire PCB board.
At the industrial PCB one-stop manufacturer PCBONLINE, the BGA welding quality control standard is to control the bubble rate below 5%. It ensured welding quality and final product performance.
And we can control it to be 3%.
As shown in the picture above, the industrial PCBA is the RK control board manufactured by PCBONLINE. Its BGA bubble rate is less than 3%<. The breakthrough of this technology tests the production capability, the precision of the equipment, and the engineers' experience.
Having learned the process and key points for industrial PCB projects, you can view 4 real example projects below!
Service: OEM
Support details:
Project Features:
Reduced procurement costs for clients by 26% through supply chain optimization, with support for installment payments.
Service: One-stop PCBA
Support details:
Project Features:
Free DFM includes PCB file impedance control line optimization to reduce signal distortion; grouping and concentrated placement of computational chips and power management chips to improve heat dissipation; and use of shielding measures to reduce EMC interference.
Service: One-stop PCBA
Support details:
Project Features:
Recommending communication modules produced in China helps customers reduce costs by 16% while maintaining performance.
Installment payment support is available.
We assist customers in simplifying their supply chain process with scheduled and timely deliveries, alleviating their inventory management costs.
Service: From R&D to mass production
Support details:
Project Features:
Intellectual property belongs to the client.
A full refund of the initial R&D costs will be provided once the bulk order reaches the agreed quantity.
Before the design phase, based on the customer's requirements for low cost and compact size, we select the most cost-effective main control chip and consider mold production costs to maximize cost savings for the customer.
You can work with the advanced PCB source factory manufacturer PCBONLINE for industrial PCBs under one roof. In industrial PCB project manufacturing capabilities, we have:
Besides industrial PCB projects, if you need higher-performance PCBs - automotive and medical-grade, PCBONLINE can also meet your project requirements! Don't hesitate to contact .
Industrial PCBs have higher reliability and performance than consumer-grade electronics. Not only industrial devices but mid to high-end consumer devices can also use industrial PCBs for their production. If you need industrial PCBs, choose PCBONLINE as your one-stop manufacturer with free DFM and the best reliable quality.
Are you interested in learning more about pcb manufacturing china? Contact us today to secure an expert consultation!
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