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26 7 月, 2024Dry Soldering: How to Prevent and Fix Dry Solder Joint?
25 7 月, 2024It’s essential to ensure that solder joints are made correctly in any electronics construction. Poor and dry soldering cause equipment not to work once. Or there is a possibility that the solder joint could fail. In this blog, we will introduce why dry soldering occurs and how to solve it.
What is Meant by Dry Soldering?
Dry soldering refers to a poor solder joint that lacks proper electrical connectivity on a PCB assembly product. This issue occurs when the solder does not properly melt and bond to the components, leading to weak connections. These joints are often brittle and prone to failure, which can result in intermittent or complete loss of electrical connectivity.
![Dry Soldering: How to Prevent and Fix Dry Solder Joint?](https://www.bestpcbs.com/blog/wp-content/uploads/2024/07/soldering.png)
Why Dry Solder Joint Causes?
Dry solder joints occur due to several reasons, each impacting the quality of the solder connection. First of all, the solder paste reflow process is only a small area, which is easier to harden than the solder paste in the solder paste can. At this time, the solder paste will not melt, and the flux cannot cover the solder joint, resulting in poor welding of the solder joint. Meanwhile, the solder paste is easier to heat transfer, and the high temperature actually makes the solder paste not easy to melt, so we can slightly adjust the reflow welding temperature curve to solve the problem, or welding in a nitrogen environment is basically a good way to solve this problem.
Secondly, the solder paste does not melt because its own composition contains a very volatile flux, which is also the reason why the solder paste is easy to harden. Among them, the flux with the largest content of solder paste is rosin, rosin contains a lot of rosin acid, rosin acid is easy to lose activity at too high temperature. Therefore, the temperature of the welding process should be controlled to ensure that the temperature is about 200 ° C, which is not suitable for too high or too low. At the same time, the quality of thixotropic agent will also lead to the solder paste is easy to dry, the quality of thixotropic agent is not good will affect the viscosity of the solder paste, the viscosity of the solder paste is easy to dry. Therefore, the choice of high-quality solder paste can fundamentally solve the problem that the solder paste is easy to harden.
In addition, the use of solder paste scene, humidity, temperature and other external factors will also affect the solder paste in the use of hard non-melting phenomenon. So these external factors should be paid attention to. I hope these solutions can solve your problems.
How Do You Fix Dry Solder?
Solder paste is one of the very important materials in the electronics industry, and it has an important impact on the production quality of the entire component. Here are some tips that can help to fix the dry solder paste.
1.Add flux
Usually, if the solder paste is too dry, you can try to add some water to the right amount of flux, stir well and add it to the solder paste. This can play a certain role in alleviating drying and improve the fluidity of the solder paste.
![Dry Soldering: How to Prevent and Fix Dry Solder Joint?](https://www.bestpcbs.com/blog/wp-content/uploads/2024/07/flux.png)
2. Take some measurements during management
a. Keep the ambient temperature moderate during storage;
b. Stir well before use;
c. Cover the solder paste in time after welding to avoid exposure to the air.
3. Replace it with new one
If the solder paste becomes too dry, adding flux is difficult to restore its original properties, it is recommended to replace the solder paste to avoid affecting the quality of the components.
Therefore, we need to regularly maintain and manage the solder paste to ensure that its quality meets the standard requirements.
What Does a Dry Solder Look Like?
Recognizing a dry solder joint is crucial for proper diagnosis and repair. Unlike a good solder joint, which is shiny and smooth, a dry joint looks matte and rough. The joint might have visible cracks or look brittle. It might not be fully bonded to the component lead or the PCB pad. Identifying these visual cues can help in quickly addressing the issue.
How Do You Prevent Dry Solder?
Preventing dry solder joints is key to maintaining the reliability of your electronic projects. You can try to use these tips to prevent your solder paste become dry.
- Proper heating
- Clean surfaces
- Use quality solder
- Steady hand
- Maintain equipment
- Fast usage and storage
If you want to know more about solutions of dry solder paste, you can read our another post, How to Solve Dry Solder Paste.
How to Tell If Solder is Bad?
Bad solder can lead to dry joints and other issues. So, how can we identify if my solder paste is bad? May you can follow these points. If everything matches up, there’s no doubt that your solder paste is broken.
- Appearance of solder joints
Bad solder joints often appear dull or matte instead of shiny and smooth. They may also show cracks or a brittle texture, indicating poor bonding or excessive heating. These visual signs suggest that the solder did not properly melt or flow.
![Dry Soldering: How to Prevent and Fix Dry Solder Joint?](https://www.bestpcbs.com/blog/wp-content/uploads/2024/07/How-to-Tell-If-Solder-is-Bad.jpg)
- Solder flow and coverage
If the solder does not adequately cover the component leads or PCB pads, or if it spreads unevenly, it is likely bad. Proper soldering should result in a well-formed, consistent fillet around the leads, ensuring reliable electrical connections.
- Difficulty in melting
Solder that requires unusually high temperatures or takes a long time to melt may be old or contaminated. Proper solder should melt easily at the recommended temperature and flow smoothly to create a solid joint.
- Contamination indicators
Oxidized or tarnished solder indicates contamination and can affect its performance. Excessive residue or debris also points to poor quality, affecting how well the solder adheres and flows.
Best Technology is a one-stop PCB manufacture and PCBA service provider, our SMT factory is equipped with more than 6 assembly lines. Meanwhile, we have automatic SPI machine and solder paste printing machine, with good management system, we can ensure the good quality of solder paste. In addition, there are many advanced equipment in our workshop, including online dual AOI, X-ray, Nitrogen reflow oven, dry-ice cleaning machine, and so on.
Trust us, we are the one of most reliable PCBA manufacturer in China and Vietnam. Contact us for more.
What is a Zero PCB Board? – Best Technology
24 7 月, 2024A zero PCB, also known as a prototype PCB or breadboard, is a type of circuit board used for building and testing prototypes. Unlike traditional PCBs, which have pre-defined paths for electric connections, zero PCBs offer a grid of holes. This grid allows for custom circuit designs using wires and components. Engineers and hobbyists use zero PCBs to experiment and develop new electronic circuits without committing to a specific design.
What is a zero PCB?
Zero PCBs are particularly helpful in testing circuit designs for any shortcomings. They provide a cost-efficient way to evaluate the circuitry before committing to a final solution. The term ‘zero’ in this context signifies a fundamental distinction. It implies that there are no predefined connections, layouts, or functions on the PCB.
![What is a Zero PCB Board? - Best Technology](https://www.bestpcbs.com/blog/wp-content/uploads/2024/07/zero-board-1.png)
Generally, there is no solder mask and silkscreen on the zero board. The primary purpose of a zero PCB is to offer a blank canvas for users to create and test custom circuits. As a result, they are intentionally kept simple in structure to allow for maximum customization. Users are free to design and solder their circuits and components directly onto the board without the constraints of a predefined layout or solder mask.
What is the use of a zero board?
Zero boards serve a variety of purposes in the electronics industry. They are particularly useful for prototyping and testing new circuit designs. Here are some common uses:
- Prototyping
- Educational purposes
- Quick fixes
- Small-scale production
Zero PCBs have a layer of copper traces or pads on the substrate. These copper elements provide the conductive pathways for soldering electronic components and forming connections. However, the copper traces on zero PCBs are usually unconnected, meaning there is no predefined circuit layout. You can build a circuit on them by inserting components into the holes and then connecting them with wires.
What is the cost of a zero PCB board?
The cost of zero PCB boards varies based on size, material, and supplier. Generally, they are quite cost-effective, so that both professional engineers and hobbyists can afford it. Prices can range from a few cents for small boards to several dollars for larger or more specialized versions. Bulk purchasing often reduces the cost per unit. Additionally, different materials, such as fiberglass or phenolic, can affect the price.
What size is a zero PCB board?
Zero PCB boards come in various sizes to accommodate different project needs. Common sizes include:
- Small: Typically around 5×7 cm, ideal for simple projects.
- Medium: Sizes like 10×15 cm offer more space for complex circuits.
- Large: Boards as large as 30×30 cm are available for extensive projects.
The grid pattern usually remains consistent, with a standard pitch of 2.54 mm (0.1 inches) between holes, regardless of the board’s overall size.
What is a bare board?
A bare board, also known as a blank PCB, is a printed circuit board that has not yet been populated with any electronic components. It is essentially the foundation of a PCB, consisting only of the substrate material (such as fiberglass) and the copper traces that form the circuit pathways. A bare board typically include base core, prepreg and copper trace layer.
![What is a Zero PCB Board? - Best Technology](https://www.bestpcbs.com/blog/wp-content/uploads/2024/07/structure-of-bare-board-1-1024x507.png)
Features of a bare board
- Substrate material
The base material of a bare board is usually fiberglass, FR4, or other insulating materials that provide mechanical support.
- Copper traces
These are the conductive pathways etched onto the substrate. They form the circuit’s electrical connections but are not yet connected to any components.
- Pads and holes
Bare boards include pads (flat areas of copper for soldering components) and drilled holes for through-hole components.
- Pre-defined layout
The copper traces and pads are arranged according to a specific design, determined during the PCB design process.
- No components
A bare board does not have any electronic components soldered onto it yet. It is essentially a “blank slate” ready to be populated.
- Coated solder mask and silkscreen
Most bare boards have a solder mask, a protective layer that prevents solder from bridging between conductive areas, and a silkscreen, which provides component labels and other information.
If you are looking for a reliable supplier for your PCB needs, consider companies like Best Technology, who is known for their quality and customer service. Best Technology offers a range of options to support your electronic projects from prototyping to production. Contact us right now to get your quotation.
PCB vs CCA: What is a Circuit Card Assembly?
22 7 月, 2024Hey there! If you’re curious about circuit card assembly (CCAs) and what makes them tick, you’ve come to the right place. CCAs are the unsung heroes behind many of the electronic devices we use every day. Let’s dive into what they are, their essential parts, how they’re made, and why they’re so important.
What is a circuit card assembly?
Circuit card assembly or CCA is the process of producing printed circuit boards. In essence, it is the same as PCBA (PCB assembly), just in different name. CCA is a manufacturing technology that converts raw materials into printed circuit boards. It is used in many industries, including the military and aerospace sectors. This type of manufacturing requires skilled professionals to lay out the design and then assemble it. If you are planning to buy a batch of circuit card components, here are some things you should know about CCA.
![PCB vs CCA: What is a Circuit Card Assembly?](https://www.bestpcbs.com/blog/wp-content/uploads/2024/07/DSC09803.jpg)
A circuit card is a thin, flat dielectric material on which conductive paths or traces are etched. These paths connect various electronic components. They are also used to connect components to sockets on printed circuit boards. Circuit card assy is the process of manufacturing circuit card components. The process involves adding electronic components to the substrate.
Key components of a circuit card assembly (CCA)
Circuit card assembly have several key components to make the circuit function properly. These can be divided into three basic components.
- Printed Circuit Board (PCB)
- Electronic component
- Solder paste
- Printed Circuit Board (PCB)
This is the backbone of the CCA. The printed circuit board provides the structural foundation on which all other components are mounted. A PCB is typically made of a flat, insulating material such as FR4 fiberglass, which is layered with conductive tracks made of copper. These tracks form the circuit pathways that connect various electronic components. The PCB board can be single-sided, with components and conductive tracks on one side only, or double-sided, with tracks and components on both sides. For more complex applications, multi-layer PCBs are used, which consist of multiple layers of insulating material and conductive pathways stacked together. These printed circuit boards are essential in ensuring that electrical signals are routed efficiently and reliably across the assembly.
![PCB vs CCA: What is a Circuit Card Assembly?](https://www.bestpcbs.com/blog/wp-content/uploads/2024/07/pcb-1.jpg)
- Electronic Components
These include resistors, capacitors, integrated circuits, transistors, and more passive and positive components. Each part plays a specific role in the circuit, like pieces of a puzzle fitting together to make a complete picture. Resistors control the flow of electrical current, capacitors store and release energy, integrated circuits (ICs) perform various functions like processing and memory storage, and transistors act as switches or amplifiers. These components are carefully placed on the PCB in positions that allow them to connect and interact as designed.
![PCB vs CCA: What is a Circuit Card Assembly?](https://www.bestpcbs.com/blog/wp-content/uploads/2024/07/DSC00005.jpg)
- Solder paste
Solder paste is like the glue that holds everything together, but it’s electrically conductive. It’s used to attach the electronic components to the PCB, so that they can stay put and work properly. Soldering creates a strong, conductive bond between the component leads and the PCB’s copper tracks. There are different types of soldering, such as lead-based and lead-free solders, each with its specific properties and applications. The soldering process can be done manually or using automated printing machines, depending on the complexity and volume of the assembly. Please noticed that solder paste should used in a very short time, otherwise, it will become dry solder paste.
![PCB vs CCA: What is a Circuit Card Assembly?](https://www.bestpcbs.com/blog/wp-content/uploads/2024/07/solder-paste.jpg)
What is the Difference Between a PCB and a CCA?
You might wonder, what’s the difference between a PCB and a CCA? Well, here’s a quick rundown:
Aspect | PCB (Printed Circuit Board) | CCA (Circuit Card Assembly) |
Definition | A blank board with conductive pathways | A PCB populated with electronic components |
Components | No electronic components | Includes electronic components like resistors, capacitors, ICs |
Functionality | Serves as the foundation for electronic circuits | A functional electronic circuit ready for use in devices |
Manufacturing Steps | Involves design, etching, and printing of conductive paths | Involves PCB manufacturing plus component placement and soldering |
Usage Stage | Intermediate stage in manufacturing | Final stage, ready for integration into electronic devices |
Complexity | Less complex, involves fewer manufacturing steps | More complex, involves multiple stages of assembly and testing |
What is the circuit card assembly manufacturing process?
Making a CCA is a multi-step process:
Design
First, the PCB layout is designed using computer software. It includes numerous steps, like schematic drawing, layout design, SI, PI analysis, DFM. This can ensure the PCB board can fit all the necessary components and function correctly.
Fabrication
The PCB is then fabricated, which involves creating the physical board with layers of insulating and conductive materials. This is where the board gets its pathways. In this step, proceed strict quality control process to make sure the bare boards are qualified.
Component Placement
Next, printing solder paste and preparing components, then place them onto the PCB board according to the BOM file (bill of material). After setting up the pick and place machine, automated machines can precisely position each component based on the design.
Soldering
The components are soldered to the PCB. This can be done using methods like wave soldering or reflow soldering to ensure everything is securely attached and electrically connected. You must know, different products require different parameters, please make sure all the parameters like temperatures, time are suitable.
Inspection and Testing
The assembled CCA goes through rigorous inspection and testing to ensure it works as intended. This includes visual inspections, automated optical inspections (AOI), in-circuit testing (ICT), aging testing and functional testing.
Final Assembly
If the CCA passes all tests, it moves on to final assembly, where it’s integrated into the larger electronic system or device. That is we say the box building assembly.
What are the types of circuit card assembly?
CCAs can be divided into various types according to the different manufacturing technology.
Through-Hole Technology (THT) Assembly
Here, components have leads or pins inserted into holes drilled through the PCB and soldered on the other side. This method provides strong mechanical bonds, making it great for components that experience mechanical stress. It’s often used in aerospace, military, and industrial equipment.
Surface Mount Technology (SMT) Assembly
In SMT, components are mounted directly onto the PCB surface using solder paste. No drilling required, which allows for higher component density and smaller PCBs. This method is commonly used in consumer electronics, telecommunications, and automotive industries.
Box Building Assembly
Box building assembly involves the complete assembly of electronic systems, including CCAs, into enclosures or boxes. This process includes not only the assembly of the PCB but also the integration of cables, connectors, and other components into a final product. Box building is ideal for producing complete electronic devices ready for end-use.
Advanced materials for CCAs
Advanced materials help CCAs perform better and last longer:
- High-Temperature Laminates (e.g., FR-4, Polyimide)
High temperature laminate like FR4 or polyimide. These materials can handle extreme conditions without breaking down. FR-4 is popular for its excellent thermal and mechanical properties, while polyimide is great for high-temperature stability.
- Flexible Substrates (e.g., Kapton, PET)
Kapton and PET are the most common flexible substrate. These materials allow CCAs to bend and flex. Kapton, a type of polyimide, is known for its high thermal resistance and flexibility, making it perfect for wearable electronics and medical devices. PET (polyethylene terephthalate) is another flexible material with good electrical insulation properties.
- Advanced Solder Compounds
SAC305 (a lead-free alloy of tin, silver, and copper) is favored for its mechanical and thermal properties. Whatever you want to mount a ceramic PCB or the flexible PCB, it is the best choice. Sn63Pb37, a traditional tin-lead solder, is still used for its ease of use and excellent performance.
Reliable circuit card assembly manufacturers
Choosing the right manufacturer for your CCAs is key to getting quality products. PCBonline and Best Technology are go-to-choice reliable circuit card assembly manufacturers. Both of them has advanced pick and place machine, full-auto SPI, AOI equipment, ensuring a good quality.
As a leading manufacturer in the circuit card assembly, Best Technology prides full turn-key service, ranging from the PCB design, PCB fabricating, electronic component sourcing, circuit card assembly and box build assembly. We handle complex and high-volume orders efficiently, ensuring timely and fast delivery without sacrificing quality. In 2023 alone, we completed over 5000 high-complexity projects with a client satisfaction rate of over 98%.
It is crucial for anyone to fullly understand the circuit card assembly in the electronics industry. From their basic components and manufacturing process to the advanced materials used, CCAs are the backbone of modern electronic devices.
How to Make a BOM?
11 7 月, 2024If you are familiar with SMT or PCB assembly process, you may know BOM file. It is an important element in the SMT process. Creating BOM is a crucial step in the manufacturing process, especially for PCBs. A BOM serves as a comprehensive list of all the parts, components, and materials needed to build your product. It ensures that everyone involved in the production process is on the same page, reducing the risk of errors and delays. Today, Best Technology would like to introduce BOM and giving you a guide to create a BOM file step by step.
![How to Make a BOM?](https://www.bestpcbs.com/blog/wp-content/uploads/2024/07/PCBA-1.jpg)
What is a Bill of Materials (BOM)?
A Bill of Materials (BOM) is a detailed list of all the parts, components, and materials needed to manufacture a product. In PCB manufacturing, a BOM outlines every item required to assemble a PCB, including quantities, part numbers, and descriptions. It serves as a guide to ensure that the manufacturing process runs smoothly and that no crucial components are missing.
Types of Bill of Materials
There are several types of BOMs used in different stages of production. Each type serves a specific purpose and provides unique details to streamline processes and ensure accuracy. Here are the primary types of BOMs:
- Engineering BOM
This type of BOM is creating during the design phase. It lists all the parts and components designed by the engineering team, including specifications and relationships as intended in the final product. And of course, it mainly used by design engineers to communicate the product structure and details to manufacturing teams.
- Manufacturing BOM (Formal)
It is a formal BOM files that used in the assembly phase. Different with engineering BOM, it includes additional details necessary for manufacturing, such as packaging, handling instructions and assembly details. And some special instructions.
- Sales BOM
Sales BOM is used by sales teams and includes information relevant to the sales process, such as pricing and availability. It helps in providing accurate quotes, managing customer expectations, and handling sales orders efficiently.
What Should Include in an Effective Bill of Materials?
An effective BOM should be detailed, accurate, and easy to understand. It should include all the details of components and indicated revisions. As a 18 years expertise in PCBA production, we summarized the key elements that should be included in the BOM.
- Component details
It should include all the components and their detailed information, such as names, part numbers (PN), and descriptions for each part.
- Quantity (QTY)
The exact quantity of each component required for the product. Accurate quantities can prevent shortages and overstocking.
- Foot print
It is the package of each component, helping to ensure the correction of part.
- Reference Designators
Unique identifiers that match each component to its specific location on the product layout. These are essential for assembly and troubleshooting.
- Manufacturer Information
Manufacturer information, including the manufacturer name of components and manufacturer part number. It helps to ensure correct parts are sourced. And convenient for alternative part sourcing if it is shortage.
- Supplier information (Optional)
It means the name of the supplier or distributor. The part number used by the supplier, which may differ from the manufacturer’s part number.
- Assembly instructions
Any special notes for assembly such as DNF remark, and version control to track revisions should also be included. Additionally, cost information helps in budgeting, and lifecycle status information helps plan for component availability and avoid discontinued parts.
How to Make a PCB Bill of Materials (BOM)?
Creating a PCB BOM is a systematic process that involves compiling all the necessary information about each component required for the assembly of the PCB. Here’s a detailed guide on how to create a PCB BOM:
- Open a Blank Spreadsheet
Use software like Microsoft Excel or Google Sheets to start with a blank spreadsheet. They are common to use, offering flexibility and ease of use for creating and managing BOMs.
- Define Columns
Set up your spreadsheet with appropriate column headers. Common headers include:
- Part Number
- Component Name
- Quantity
- Reference Designator
- Manufacturer
- Manufacturer Part Number
- Supplier
- Supplier Part Number
- Description
- Package Type
- Cost
- Notes
- Input Data
Enter the required details for each component under the appropriate headers. Please be make sure that all information is accurate and complete. This may involve referencing design files, datasheets, and supplier catalogs. If it is incorrect, then it needs a lot of time to find out and revise the errors, resulting in schedule delay.
- Use Formulas
Utilize Excel formulas to automate calculations, such as summing total quantities or calculating costs. This helps in reducing manual errors and saves time.
- Format for Clarity
Use cell formatting options to highlight important information and ensure the spreadsheet is easy to read. For example, you can use bold text for column headers, color coding for different component types, and borders to separate sections.
- Include Version Control
Add a version control section to your BOM to track revisions and updates. This can be a simple row at the top or bottom of the spreadsheet, indicating the version number, date of revision, and a brief description of changes.
![How to Make a BOM?](https://www.bestpcbs.com/blog/wp-content/uploads/2024/07/BOM-file-1024x346.png)
- Save and Update
Save your BOM and update it regularly to reflect any changes in the design or component availability. Regular updates ensure that the BOM remains accurate and up-to-date, preventing issues during production.
- Review and Verify
Have multiple team members review the BOM for accuracy. Cross-check all component details, quantities, and part numbers against the design files. Verification helps catch errors early and ensures the BOM is reliable.
- Communicate with Suppliers:
Maintain open communication with suppliers to confirm component details and availability. This ensures that you can source the correct parts and avoid delays in the production process.
How Can I Optimize My BOM for PCB Assembly?
Sometimes, a simple BOM is not good to process PCB assembly process, and manufacturers may need to spend a lot of time to optimize it, make into convenient for manufacturing. If you are a layman, here are some steps to help you in optimizing your BOM file.
First, it’s a good idea to standardize components where possible. Using standard parts that are readily available from multiple suppliers can simplify procurement and reduce costs. This approach minimizes the risk of shortages and ensures you can get parts quickly and affordably. Also, make sure all entries in your BOM are clear and concise to avoid confusion during assembly. Double-checking part numbers and quantities against design files is crucial to prevent errors that could lead to rework or delays.
Building strong relationships with your suppliers is another key factor. Good communication with suppliers helps ensure reliable component availability and keeps you informed about any changes in lead times or part availability. Regularly updating your BOM to reflect any design changes or component availability issues is essential. Keeping your BOM current and accurate prevents last-minute surprises during assembly.
![How to Make a BOM?](https://www.bestpcbs.com/blog/wp-content/uploads/2024/07/BOM-file-check.jpg)
What Common Mistakes Should I Avoid When Creating a PCB BOM?
Avoiding common mistakes in BOM creation can save time and reduce errors. Here are some pitfalls to watch out for:
- Incomplete information – ensure all necessary details are included for each component.
- Incorrect quantities – double-check quantities to avoid shortages or excess inventory.
- Outdated data – keep the BOM updated with the latest design changes and component information.
- Ambiguous descriptions – provide clear and precise descriptions to prevent confusion.
- Lack of version information – implement version control to track changes and ensure the correct BOM version is used.
Creating an effective and accurate PCB BOM is essential for smooth manufacturing and assembly. By following best practices and using the right tools, you can ensure your BOM is comprehensive, clear, and up-to-date, ultimately leading to a successful PCB production process.
Best Technology is an expert in SMT and PCB assembly, we have more than 18 years in this industry, that can offer you a best experience of PCBA solution. In our facotry, we have advanced equipment like full auto pick and place machine, online dual AOI, X-ray, 3D SPI, nitride reflow oven and three-proof paint machine. So that we can ensure the fast lead time and high quality of your PCBA products. Reach us to get a instant quote!