In modern electronics manufacturing, PCBA (Printed Circuit Board Assembly) has become a core component of electronic product production. For many clients, understanding the complete PCBA process not only aids in project planning but also helps in selecting the most suitable service provider. This article provides a detailed overview of the one-stop PCBA manufacturing process and its advantages.

Complete One-Stop PCBA Process Breakdown

1. Circuit Board Design

  • Tools: Utilize EDA software such as Altium Designer and Eagle to complete circuit schematics and PCB layout, specifying component placement, routing, and interlayer connections.

  • Output: Generate Gerber files and a BOM (Bill of Materials) to support subsequent manufacturing stages.

2. Raw Material Preparation and PCB Fabrication

  • Base Materials: Use FR-4, high-frequency boards, etc., processed via etching, drilling, electroplating, and solder mask application to form the PCB.

  • Key Control Points:

    • Layer alignment accuracy: ±0.05mm

    • Copper plating in via walls: ≥20μm

    • Solder mask adhesion: Meets ASTM D3359 standard

3. Component Procurement and Inspection

  • Procurement: Acquire chips, resistors, capacitors, etc., based on the BOM, conforming to IPC-7351 packaging standards.

  • Inspection:

    • Visual: Packaging integrity, clear labeling, oxidation-free pins

    • Functional: Sampling tests for chip operation, resistance, and capacitance values

    • Special Handling: Moisture-sensitive devices (MSDs) must be vacuum-sealed and baked within 12 hours (125℃ for 24h)

4. SMT Assembly

  • Solder Paste Printing: Stencil thickness tolerance ≤±10μm; solder paste thickness: 0.1–0.15mm

  • Component Placement: High-speed pick-and-place machines with ±0.05mm accuracy; supports 01005 components (0.4×0.2mm)

  • Reflow Soldering:

    • Temperature Profile:

      • Preheat: 150–180℃ for 60–90s

      • Reflow: 215–235℃ for 40–60s

      • Cooling: <5℃/s

    • Solder Joint Criteria: ≥75% pad coverage, no misalignment or bridging (per IPC-A-610 standards)

5. DIP Insertion and Wave Soldering

  • Insertion: Manual or automated insertion of connectors, electrolytic capacitors, etc.; leads should be flush and not obstruct solder pads

  • Wave Soldering:

    • Control Parameters: Wave height: 1–2mm; soldering time: 3–5s; preheat temperature: 90–110℃

    • Key Metrics: ≥75% hole fill; avoid bridging or cold solder joints (verified via X-ray)

6. Testing and Quality Control

  • Electrical Testing:

    • ICT (In-Circuit Testing): Checks for circuit continuity and component values (resistance, capacitance, inductance)

    • FCT (Functional Test): Simulates real-world operating conditions (e.g., voltage, temperature) to verify I/O performance

  • Environmental Testing:

    • High-low temperature cycles (-40℃ to +85℃, 100 cycles)

    • Vibration test (random vibration 5G/15 min)

  • Visual Inspection:

    • AOI: Checks solder joint quality, polarity, and placement errors (error rate ≤0.001%)

    • X-Ray: Inspects hidden joints on BGA, QFN; void rate ≤25%

7. Conformal Coating and Packaging

  • Coating: Spray polyurethane or silicone with a film thickness of 20–50μm; salt spray resistance ≥96h (per ASTM B117)

  • Packaging: Anti-static bags + vacuum aluminum foil bags, with desiccants and humidity indicator cards (HIC) to monitor environment

One-Stop PCBA Manufacturing

PCBA Manufacturing Lead Time

The turnaround time for PCBA manufacturing varies based on project complexity and production volume:

  • Simple single-sided boards: 5–7 working days

  • Double-sided or standard multilayer boards: 8–12 working days

  • High-complexity designs or special requirements: 12–15 working days

Flexible production scheduling and expedited services are available to meet urgent customer needs.

Why Choose One-Stop PCBA Manufacturing Services?

Our professional and efficient turnkey PCBA solution offers the following significant advantages:

  1. Fully Integrated Process
    From PCB design and component sourcing to assembly and testing, we provide end-to-end services that save clients both time and cost.

  2. Quality Assurance
    With a strict quality control system, every product undergoes multiple inspections and testing to ensure reliable performance.

  3. Cost-Effectiveness
    Our in-house production capabilities and stable supply chain help deliver high-quality results at competitive prices.

  4. Technical Support
    A skilled engineering team offers design optimization advice and technical consultation to resolve various manufacturing challenges.

  5. Fast Delivery
    Advanced production equipment and refined management processes ensure timely and efficient delivery.

summary

One-stop PCBA manufacturing refers to a comprehensive service covering the entire process from PCB fabrication, component procurement, SMT assembly, DIP insertion, and functional testing, to final assembly and packaging. Clients only need to provide design documentation, while the supplier completes all production tasks. This approach saves time, effort, and cost, ensures better quality control, and is especially suitable for enterprises that demand high efficiency and product reliability.