Archive for the ‘PCBA’ Category

SMT PCB Manufacturer, SMT PCB Manufacturing Process

Friday, April 11th, 2025

SMT PCB manufacturer services are the backbone of modern electronics. Whether you’re building a smartphone, a wearable device, or an industrial controller, you need precision. These manufacturers combine automation, experience, and consistency to help your products come to life. In this blog, you’ll learn how SMT works, what to look for in a supplier, and who the key players are in different markets.

Best Technology is a professional SMT PCB manufacturer. Our SMT factory was established in 2015. SMT PCB quality is our bloodstream. Our Quality Policy commits to customer delight through full engagement. We will achieve a quality and reliable SMT PCB passing rate of 98% by solving customer complaints within 24 hours in 2025. Our product portfolio encompasses Metal Dome, Metal Dome Array, Flexible Printed Circuits (FPC), Rigid PCBs (FR4 PCB), Rigid-Flex Circuits, Metal Core PCBs, Ceramic Substrate PCBs, PCB Assembly Services (SMT/PCBA Manufacturing). These solutions power virtually all modern electronic devices, spanning consumer electronics, automotive systems, medical equipment, and industrial automation applications.

Every PCB product listed above from Best Technology is fully customizable, just feel free to let us know your specific SMT PCB requirement via sales@bestpcbs.com.

SMT PCB Manufacturer, SMT PCB Manufacturing Process

What is SMT in PCB Manufacturing?

Surface Mount Technology, or SMT, refers to placing components directly onto the surface of a PCB. It has replaced the older through-hole method in most modern assemblies. SMT enables smaller, lighter boards with higher component density. This makes it ideal for compact electronic devices.

Unlike the older process, SMT does not need holes drilled into the board. Instead, tiny components are placed using automated machines. Then, solder paste and heat secure the parts firmly in place. The result is efficient and cost-effective production.

What Services Does an SMT PCB Manufacturer Offer?

A professional SMT PCB manufacturer typically offers full-service support. Here are the most common ones:

Component sourcing: Reliable sourcing ensures all parts meet the quality standard.
Stencil design and paste printing: Precision in paste application impacts the entire process.
Pick and place services: Robotic arms place components with high accuracy.
Reflow soldering: Heat is applied to solidify the solder paste.
Inspection and testing: AOI, X-ray, and functional tests ensure product reliability.

Some manufacturers go beyond this with turnkey solutions. This includes design support, box build, and logistics.

SMT PCB Manufacturing Process

The SMT PCB manufacturing process is built around accuracy and speed. An SMT PCB manufacturer like Best Technology follows a strict, detailed process to ensure each board performs reliably in real-world conditions. Our workflow is built for precision, consistency, and speed — especially for projects with demanding specs and tight lead times.

Step 1: Incoming Material Inspection (BGA/PCB)

Every journey starts with quality. Our team inspects the incoming PCBs and BGA components before they enter the line. We check for warpage, oxidation, and conformity to IPC standards.

Step 2: Baking (Dehumidification)

Next, we bake moisture-sensitive parts like BGA, IC, FPC, SMD LED and bare PCBs in a temperature-controlled oven. This prevents internal moisture from causing delamination or popcorn effect during reflow.

Step 3: Solder Paste Preparation

We prepare the solder paste by mixing and thawing it under controlled conditions. This step avoids separation of flux and metal particles, ensuring a smooth application.

Step 4: Solder Paste Printing

Using high-precision printers and stainless steel stencils, we print solder paste onto each PCB pad. This step is critical, which sets the foundation for perfect component placement.

Step 5: SPI (Solder Paste Inspection)

Before going further, we inspect every board using SPI machines. They check solder paste height, volume, and alignment. If any deviation is found, it’s corrected immediately.

Step 6: Component Placement (SMT)

Now comes the core of SMT — pick and place. Our automatic machines accurately place each SMD component, from resistors to complex ICs, onto the solder-pasted PCB surface.

Step 7: Reflow Soldering

Once the components are placed, boards move into our reflow oven. They pass through a multi-zone system where controlled heat melts the solder and solidifies electrical connections without damaging components.

Step 8: Tail End Cleaning

After reflow, we clean any excess flux or debris that might affect the final inspection or future use. This keeps the surface clean for the next steps.

Step 9: Post-Reflow Inspection

Every board undergoes manual and machine-assisted inspections. We check for solder bridging, cold joints, and other visible defects.

Step 10: AOI (Automated Optical Inspection)

Our AOI machines scan each board to detect alignment errors, missing components, or improper solder joints. This step eliminates most visual flaws before the next process.

Step 11: X-Ray (for BGA only)

If the board includes BGAs, we inspect solder joints hidden under the package using X-ray equipment. It ensures full connectivity and proper wetting under these tricky parts.

Step 12: Hand Soldering (Post-SMT)

Some connectors, pin headers, or through-hole parts are added manually. Our skilled operators solder them carefully to maintain stability and cleanliness.

Step 13: Cleaning

Boards go through a cleaning process again to remove any flux residues, especially after hand soldering. This improves long-term reliability and electrical insulation.

Step 14: Programming and Testing

Functional tests come next. We flash firmware, check voltages, run diagnostics, and validate every circuit performs to spec. Failed boards are fixed or flagged for review.

Step 15: Conformal Coating

If required, we apply protective coatings to safeguard against moisture, dust, and chemicals. This is vital for industrial, automotive, or outdoor applications.

Step 16: Potting/Glue Application

In some cases, we apply epoxy or adhesive gel for mechanical strength or insulation. This prevents vibration damage or corrosion in harsh environments.

Step 17: Final Assembly

At this stage, we perform product-level assembly — adding housings, displays, connectors, or mechanical parts as needed. This is where your PCB becomes a full product.

Step 18: Labeling

We add barcodes, serial numbers, or customer-specific labels. This step helps in tracking, traceability, and logistics.

Step 19: Depaneling

If boards were produced in panels, we now separate them using routers, V-cut machines, or lasers. Each piece is carefully handled to avoid damage.

Step 20: Packing Method Confirmation

Before packaging, we confirm the right shipping method with you — whether that’s anti-static bags, blister trays, bubble wrap, or custom trays.

Step 21: Final Packaging and Shipping

Boards are packed securely for local or international shipping. We make sure each box is labeled, padded, and ready for safe delivery to your door.

This entire SMT PCB manufacturing process reflects Best Technology’s dedication to consistency, cleanliness, and quality control. Whether you’re prototyping or scaling up for mass production, our process is built to support you every step of the way. Every step affects yield and quality. So Best Technology invests in modern SMT machines and skilled operators.

Who is the Top 10 Biggest SMT Company in the World?

Introduction

When searching for a global SMT PCB manufacturer, many companies lead in capacity, quality, and innovation. These firms support industries like telecom, automotive, consumer electronics, and aerospace.

Top 10 Global SMT Companies (Not in ranking order):

1. Best Technology (China) – Known for speed and flexibility in SMT PCB manufacturing.

2. Foxconn (Taiwan) – Major Apple supplier and global electronics giant.

3. Flex Ltd. (Singapore) – Offers large-scale EMS and design services.

4. Benchmark Electronics (USA) – High-reliability assemblies for aerospace and defense.

5. Sanmina (USA) – Full-service EMS with global footprint.

6. Celestica (Canada) – Supports complex, regulated industries.

7. Venture Corporation (Singapore) – High-value manufacturing and R&D.

8. Zollner Elektronik AG (Germany) – Family-run and respected in Europe.

9. Pegatron (Taiwan) – OEM and ODM services for global tech firms.

10. Asteelflash (France) – Fast-growing EMS company across four continents.

These global players have set benchmarks for SMT PCB manufacturing. Their investment in smart factories and automation gives them a leading edge. Choosing such a company brings reliability, scalability, and strong support.

SMT PCB Manufacturer in USA

The USA has long been a hub for innovation. SMT PCB manufacturers here serve high-tech, aerospace, and medical markets. Customers in these sectors need strict quality control, fast turnaround, and confidentiality.

Leading SMT PCB Manufacturers in the USA:

1. Advanced Circuits (Colorado) – Offers full turnkey PCB assembly and prototypes.

2. Tempo Automation (California) – Focused on fast, agile prototyping for startups and engineers.

3. Sanmina (California) – One of the largest electronics manufacturers with global reach.

4. Jabil (Florida) – Offers advanced automation and smart factory support.

5. Emerald EMS (California and Massachusetts) – Focuses on low to mid-volume precision builds.

Working with a USA-based SMT PCB manufacturer brings access to certified facilities and close communication. These companies are ideal for time-sensitive and highly-regulated applications.

SMT PCB Assembly Manufacturers in India

India is growing as a strong force in the electronics manufacturing scene. SMT PCB assembly manufacturers in India offer cost-efficient services with quick turnaround. Many also support large volumes for export markets.

Top SMT PCB Assembly Manufacturers in India:

1. SFO Technologies (Kochi) – A NeST group company with global client base.

2. Dixon Technologies (Noida) – Manufactures for top consumer brands.

3. Sahasra Electronics (Rajasthan) – Focused on LED and industrial PCBs.

4. Kaynes Technology (Mysore) – Offers complete EMS and box builds.

5. Vinyas Innovative Technologies (Bangalore) – Serves aerospace, defense, and industrial sectors.

India’s SMT PCB manufacturers combine affordability with strong engineering talent. As demand rises, these firms are expanding capacity to meet global needs.

What Makes a Good SMT PCB Manufacturer Stand Out in the Market?

Reputation alone doesn’t guarantee results. A strong SMT PCB manufacturer shows excellence through:

Reliable delivery time
High yield rates
ISO and industry certifications
Transparent communication
Support with design-for-manufacturing (DFM)

Smart buyers look at case studies, reviews, and production capabilities. A well-managed factory with modern SMT lines can save time and cost in the long run.

How to Choose the Right SMT PCB Manufacturer for Your Project?

Picking the right partner isn’t just about price. Here’s what to consider:

1. Capability Match – Do they handle your board size, volume, and component types?

2. Certifications – Look for ISO 9001, IATF 16949, or others depending on your sector.

3. Responsiveness – A good supplier communicates quickly and clearly.

4. Turnkey Options – One-stop services often reduce lead times.

5. Location – Proximity to your team or market may offer speed or cost advantages.

Take time to ask questions. Visit the facility if possible. Or review sample reports from past jobs.

In conclusion, choosing the right SMT PCB manufacturer improves your product’s reliability, lowers cost, and shortens launch time. Look for a partner who listens, adapts, and delivers consistently. Whether you’re working with a local firm or a global giant, trust and technical support matter the most.

If you’re looking for a reliable SMT PCB partner, Best Technology brings 18+ years of experience in custom PCB solutions. From prototypes to volume orders, we provide fast support at any time, just feel free to contact us via sales@bestpcbs.com.

Tags:SMT PCB Manufacturer, SMT PCB Manufacturing Process
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LED PCB Mount, LED PCB Mount Manufacturer

Tuesday, April 8th, 2025

Are you looking for a good LED PCB Mount service? In this blog, Let’s learn the types, infrared benefits, automated solutions of LED PCB Mount, and tips for choosing LED PCB Mount manufacturers.

Choose Best Technology for your LED PCB mount needs. We excel in premium material selection, offering thermally optimized solutions tailored to your requirements. Our state-of-the-art engineering ensures ±0.05mm tolerances, guaranteeing seamless LED integration and superior heat dissipation. Rigorous thermal testing and simulations validate every design, ensuring peak performance. Compliant with UL, CE, and RoHS standards, our solutions meet global safety and environmental benchmarks. Plus, our scalable production and responsive support make us the ideal partner for projects of any size. Contact us today for a quote: sales@bestpcbs.com

What is LED PCB Mount?

An ‌LED PCB mount‌ refers to a light-emitting diode (LED) designed to be securely attached to a printed circuit board (PCB). These components are integral to modern electronics, combining the LED’s light-generating capabilities with the PCB’s ability to provide electrical connections, structural support, and thermal management.

What Are the Types of LED PCB Mounting?

LED PCB mounting methods vary by technical approach, each suited to specific needs:

Through-Hole (DIP)‌-LEDs mounted via pins in drilled PCB holes; manual assembly, low cost, suited for basic indicators.
Surface-Mount (SMT/SMD)‌-Automated soldering onto PCB surface; compact, high-density, dominant in electronics/displays.
Chip-on-Board (COB)‌-Bare dies bonded to PCB and resin-coated; high brightness, uniform light for commercial/auto lighting.
Metal-Core PCB (MCPCB)‌-Aluminum/copper substrates for high-power LEDs; superior heat management in streetlights/auto headlights.
Flip-Chip‌-Dies mounted upside-down with solder bumps; reduces resistance, improves thermal/electrical performance.
Integrated Modules‌-Pre-built units with LEDs, drivers, and optics; plug-and-play for smart lighting/IoT systems.

What Are the Benefits of Infrared LED PCB Mounts?

Superior Heat Dissipation‌: Metal-core PCBs (e.g., aluminum) manage high heat from IR LEDs, ensuring stable performance and extended lifespan in thermal-sensitive applications.
Robust Performance in Harsh Environments‌: Durable mounting (e.g., SMT/COB) and corrosion-resistant materials withstand vibrations, humidity, and extreme temperatures for industrial/outdoor use.
Miniaturized Design & Scalability‌: SMT enables compact, high-density layouts for space-constrained devices, while automated production cuts costs for mass-market adoption.
High Signal Consistency‌: Precision mounting minimizes electrical noise, ensuring reliable IR output for communication (e.g., remote controls, LiDAR).
Customizable Optical Output‌: Tailored PCB designs optimize wavelength focus (e.g., 850nm/940nm) for biometrics, surveillance, or medical systems.

What Are Removable LED PCB Mount Connectors For?

Modular Maintenance & Upgrades-Replace or upgrade LED modules without soldering, drastically reducing system downtime.
Flexible System Design-Reconfigure LED layouts (color, brightness) by swapping modules, adapting to dynamic needs.
Hot-Swappable Reliability-Replace faulty units during operation, ensuring continuous performance in critical applications.
Simplified Inventory-Standardize connectors across products to minimize stock complexity and costs.
Cost-Efficient Repairs-Fix issues by replacing only damaged modules, avoiding waste of entire PCBs.

What’s the Best Way to Mount LEDs on PCBs?

The optimal method to mount LEDs on PCBs depends on specific application requirements but generally prioritizes these factors:

Thermal Management Integration

Use SMT or THT mounting with thermally conductive pads/vias to channel heat away from LEDs.
For high-power LEDs, attach external heatsinks via screw mounts or thermal adhesives.

Mechanical Stability

Employ press-fit connectors to protect against vibration/shock in harsh environments.
Use underfill epoxy for SMD LEDs on flexible PCBs to prevent solder joint failure.

Serviceability & Upgrades

Implement modular magnetic or plug-in connectors for tool-free maintenance.
Design symmetrical layouts with standardized footprints to simplify component swaps.

EMC Compliance

Isolate LED drivers using grounded shielding cans or dedicated PCB layers.
Route high-speed traces away from LED power circuits to minimize EMI.

Manufacturing Efficiency

Opt for SMT for automated assembly lines, reserving THT for heavy-duty components.
Use pick-and-place fiducial markers to improve placement accuracy during reflow.

Optical Performance

Angle LEDs strategically using reflective PCB solder masks or integrated lenses.
Maintain consistent phosphor coating thickness in white LEDs through controlled dispensing.

How Do You Choose LED PCB Mount Manufacturer?

When selecting an LED PCB mount manufacturer, prioritize these five critical factors:

Material Expertise-Verify they use high-quality, thermally conductive materials (e.g., aluminum, copper alloys) and offer customization for specific thermal requirements.
Precision Engineering-Ensure their machining/casting processes meet tight tolerances (±0.05mm) to ensure proper LED alignment and heat dissipation.
Thermal Testing Capabilities-Confirm they perform thermal simulations and real-world testing (junction temperature monitoring) to validate designs.
Compliance Certifications-Check for certifications like UL, CE, and RoHS to ensure adherence to electrical safety and environmental standards.
Scalability & Support-Choose manufacturers with automated production lines for volume orders and responsive engineering support for custom designs.

How Do Automated Machines Improve LED PCB Mount?

Precision Enhancement‌

Machine vision systems align components within ±0.01mm tolerance.
Automated optical inspection (AOI) detects defects like tombstoning or misalignment, reducing manual rework by 90%.

Speed & Efficiency‌

High-speed SMT machines place over 25,000 components per hour.
Integrated UV-LED curing reduces bonding time to under 3 seconds per PCB.

Quality Consistency‌

X-ray inspection ensures solder joint integrity for critical applications.
Programmable controls standardize parameters (solder paste volume, pressure) to eliminate batch variations.

Miniaturization Support‌

Robots handle ultra-small components (e.g., 0201/01005 LEDs) for compact designs.
Multi-axis systems manage complex layouts (double-sided mounting) seamlessly.

Cost & Safety Benefits‌

Precision dispensing reduces material waste by 15%.
Enclosed systems minimize worker exposure to hazards like toxic fumes.

Can 4PDT Red LED PCB Pushbutton Switches Be Mounted on PCB?

Yes‌, 4PDT red LED PCB pushbutton switches are designed for PCB mounting, featuring through-hole solder terminals that align with standard PCB layouts. Ensure compatibility by verifying the pin count/spacing (e.g., 8-pin, 19x13mm hole spacing), LED voltage (e.g., 12V or 5V), and switch ratings (e.g., 250V AC, 8A). Always cross-check the datasheet for mechanical/electrical specifications to match your PCB design.

In conclusion, that’s all about LED PCB mounting. If you have any issues with LED PCB mount, please leave a message below this blog.

Tags:LED PCB Mount, LED PCB Mounting
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What is the Meaning of PCBA? PCBA Process

Tuesday, April 8th, 2025

What Does the PCBA Stand For?

PCBA stands for Printed Circuit Board Assembly.

It’s a complete board where all parts are mounted and ready to work. The bare board itself is called a PCB. But once components like resistors, capacitors, and chips are soldered onto it, it becomes a PCBA. Sometimes, some electronic accessories will be soldered onto the PCB surface as well.

What is the Meaning of PCBA? PCBA Process

Key Components in PCBA

The value of a PCBA comes from the components it carries. Each part plays a role in how the circuit works. Let’s go over some of the most common parts:

Resistors: Control the flow of current.
Capacitors: Store and release energy when needed.
Inductors: Manage signals, especially in filters.
Diodes: Let current flow in one direction only.
Transistors: Switch or amplify signals.
ICs (Integrated Circuits): Small chips with many tiny parts inside. They perform complex functions.
Connectors: Help connect the board with other systems.
Transformers: Change voltage levels for safer or better operation.

All these parts must be carefully chosen and placed. A small mistake can stop the board from working right. That’s why design and assembly matter so much.

Types of PCBA Assembly Techniques

1. Surface Mount Technology (SMT)

This is the most common method today. Components are placed directly on the surface of the board. Pick and place machines handle most of the work, which keeps it fast and accurate. SMT supports miniaturized parts and high-speed production.

2. Through-Hole Technology (THT)

This technique uses components with leads that go through holes in the PCB. These leads are soldered on the other side. THT is strong and used for large or high-stress parts like connectors or transformers.

3. Mixed Technology Assembly

Some boards use both SMT and THT. Surface-mount parts go on first, then through-hole components are added by manually. This mix allows for flexible, compact, and reliable designs.

What is the difference in PCB and PCBA?

Though the terms PCB and PCBA are often used together, they describe very different stages in the electronics manufacturing process. And you must to know: PCB are one of important part of PCBA, but PCBA not. Below we listing the key differences between them:

Factor	PCB	PCBA
Stage	Blank board	Assembled with components
Components	No	YES
Functionality	Non-functional	Fully operational
Manufacturing Cost	Low	Higher (because include the components cost)
Testing	Basic inspection	Complete electrical testing
Assembly Techniques	Not applicable	SMT, THT, or hybrid
Files Needed	Gerber, drill files	Gerber, BOM, pick & place, assembly files
Lead Time (under same design)	Short	Related longer than PCB

What Is the Use of PCBA?

PCBAs are used in almost everything you see around:

Phones: Control your screen, camera, and sound.
Computers: Process data, run programs.
Vehicles: Support GPS, safety features, engine control.
Medical devices: Power equipment like MRI or ECG machines.
Home appliances: From smart TVs to microwave ovens.

Without a PCBA, none of these would work. It’s like the brain of any electronic device. From simple tools to high-end gadgets, PCBA plays a big role.

How to Do PCBA Testing?

Testing makes sure the board works as expected. It helps catch issues before the board goes into the final product. There are several ways to test a PCBA:

1. Visual Inspection

This is the first step. Technicians or machines check if parts are in the right place. They also look for bad solder joints, cracks, or missing items.

2. Automated Optical Inspection (AOI)

AOI mainly uses a camera system scans the board. It checks for incorrect or misaligned parts. It’s faster than manual inspection and works well for large batches.

3. In-Circuit Testing (ICT)

ICT checks each component directly. It makes sure resistors, capacitors, and connections work properly.

4. Functional Testing

This test powers the board and simulates how it will be used. It checks whether the PCBA can perform the expected tasks.

5. X-Ray Inspection

Used when components are hard to see, like BGAs (Ball Grid Arrays). The X-ray looks through the board to catch hidden problems.

6. Flying Probe Test

For small batches, probes test different points without a custom fixture. It’s flexible and cost-effective.

7. Testing with jig

This is used for mass production, jig tools are made according to the design files, so it is a customized. Jig testing can save much time compared with flying probe.

Best Technology deeply know the importance of the product quality, so we pay more attention to the PCB board quality checking process. We set a QC department according to ISO9001:2015 and ensure all processes are compliance with quality system.

How Do You Clean a PCBA?

During the PCB assembly process, cleaning a PCBA is an important step, especially after soldering. Residual flux, dust, or moisture can affect the performance of the board. Nowadays, the common cleaning methods used in Best Technology are:

1. Manual Cleaning

This is the most basic method. A technician uses a soft anti-static brush and high-purity isopropyl alcohol to remove visible flux or dirt. It’s ideal for prototypes, small batches, or after rework or repair. Manual cleaning gives the operator control, especially in tight or delicate areas. However, it’s time-consuming and not suitable for large-scale production.

2. Ultrasonic Cleaning

Ultrasonic cleaning is widely used for complex boards and mass production. The PCBA is submerged in a tank filled with a cleaning solution. High-frequency sound waves pass through the liquid, creating microscopic bubbles. These bubbles collapse rapidly, producing a scrubbing action known as cavitation.

This technique reaches tiny gaps under components where brushes can’t go. It’s very effective for removing dried flux, fine dust, or ionic contamination. The process is gentle on components but powerful enough to clean even the most compact assemblies. After cleaning, the board is rinsed and dried with warm air or placed in a drying chamber.

3. Dry Ice Cleaning

Dry ice cleaning is a newer, eco-friendly technique. It uses solid CO₂ pellets, also called dry ice, blasted at high speed onto the PCBA surface. As the pellets hit, they turn into gas instantly. This process lifts off dirt, flux, and even adhesives without leaving moisture or residue behind.

Dry ice cleaning works well for delicate electronics and is especially useful in industries where cleanliness must meet strict standards. To give customer a highest quality of the PCBA, our SMT factory equipped with the dry ice cleaning machine to ensure a clear surface while improve the efficiency.

PCBA Assembly Process

The PCBA assembly process is relatively simple than PCB manufacturing, actually the most tedious step is to load all the components on the pick and place machine, and set the program parameters. Here we break down all the processes of the mass production PCB assembly, from the solder paste printing to function testing.

1. Solder Paste Printing

First, solder paste is applied to the bare PCB. This paste is mainly consists of silver and tin, a mix of tiny solder particles and flux. A stencil is placed over the board, and the paste is spread across it using a squeegee. The paste sticks only to the exposed pads where components will be mounted.

2. Load components feeder

Load all the components in the feeder of the pick and place machines, make sure all the parameter of components are correct, and double check the direction of chips. It is a simple but tedious step and need much time to check everything is okay.

2. Pick and Place

After applying solder paste, automated pick-and-place machines begin placing surface-mount components onto the board. These machines work fast and accurately. They follow a file created during PCB design that tells them the exact location for each part. The components sit on the solder paste, which holds them in place temporarily.

3. Reflow Soldering

Next, the assembled board goes through a reflow oven. The oven slowly heats the board in stages. When it reaches a high enough temperature, the solder paste melts and forms strong electrical and mechanical connections between the parts and the board. After this, the board cools down, and the solder solidifies.

This step is only for SMT components. If the board has only through-hole parts, this step may be skipped.

4. Inspection (AOI and Visual)

Once the soldering is done, the board goes through inspection. Automatic Optical Inspection (AOI) machines scan the board using high-resolution cameras. They check for misaligned parts, soldering problems, or missing components. For small production or sensitive areas, manual inspection is also performed to catch anything machines might miss.

5. Through-Hole Component Insertion (If Needed)

If the board uses through-hole technology (THT), this is when those parts are added. Workers or machines insert the components into the holes, and the leads go through to the other side of the board. These components are often bulkier, like connectors or transformers.

6. Wave Soldering (For THT)

For boards with many through-hole parts, wave soldering is used. The board passes over a wave of molten solder that touches the underside. This solders all the leads at once. It’s fast and effective, especially for high-volume production. For small-scale or sensitive boards, hand soldering might be used instead.

7. Final Inspection and Quality Control

After soldering, the entire board is checked again. Technicians or AOI machines inspect the final assembly. They look for cold joints, excess solder, or misplaced parts. Boards may also be tested with X-ray machines to inspect solder joints under BGAs or hidden areas.

8. Functional Testing (FCT)

The next step is functional testing. The board is powered up and tested to make sure it works correctly. This could include checking voltages, signals, response times, and communication with other devices. Engineers may use test jigs or test programs based on the end application.

9. Cleaning (If Needed)

After all soldering and testing, the board might be cleaned to remove flux residue. Depending on the flux used, this could be manual, ultrasonic, or dry ice cleaning. Clean boards are especially important in high-reliability fields like aerospace, automotive, or medical.

10. Conformal Coating or Protection (Optional)

For some applications, a conformal coating is applied. This is a protective layer that shields the board from moisture, dust, and chemicals. It’s often used in harsh environments. Coating can be applied by spraying, dipping, or brushing.

11. Packaging and Shipping

Finally, once the PCBA passes all checks, it’s packed carefully. Anti-static bags, foam, and trays protect it during transport. Labels are added for tracking and traceability. From here, it’s ready to be installed into the final product. Here is a whole process of pcb assembly in Best Technology.

PCBA HS Code

Every product for trade needs a code. The HS code for PCBA usually is 8517799000

But depending on the use or market, some customs may use a different classification. For example:

853400 for bare board parts, sometimes be used on certain assembled parts.

847330 for boards used in computers.

853710 for board which used as controller or controller unit.

Noted: Always check with your country’s customs for the right code. Using the wrong one may cause delays or extra costs.

Our PCBA Services

At Best Technology, we specialize in end-to-end PCBA services. From design to delivery, we support your project with speed, quality, and reliability. We can be your first choice because:

We have 18+ years in PCB industry
One-Stop Service: PCB fabrication, parts sourcing, SMT/THT assembly, testing
Custom Solutions: From prototypes to mass production, no MOQ
Skilled Engineers: For DFM & DFA checks and process optimization
Strict Quality Control: 9-times QC check, including AOI, X-ray, ICT, and functional testing
Global Delivery: Fast and on time, wherever you are
Component Sourcing: Only original, trusted parts, we have cooperated with digikey, findchips, mouser for over 10 years, and we can get the most competitive price from them.
PCB Fabrication: Rigid, flex, metal-core, ceramic, and more.

Whether you’re working on a simple control board or a multi-layer high-speed system, we’re here to support you.

Tags:meaning of pcba, PCBA, pcba process
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How to Embedded System Interact with Various Sensors?

Friday, March 28th, 2025

Embedded systems are at the core of modern technology, enabling devices to interact with their environment in intelligent ways. These systems rely on sensors to collect real-world data and use microcontrollers to process and respond to that data. From smart homes to industrial automation, embedded systems play a vital role in optimizing efficiency and automation.

What is a Sensor in an Embedded System?

A sensor in an embedded system is a device that detects and measures physical properties such as temperature, pressure, motion, or light and converts them into electrical signals. These signals are then interpreted by a microcontroller or processor to make real-time decisions.

Sensors serve as the system’s primary interface with the external environment. They can measure a wide range of physical and chemical properties, including:

Temperature (e.g., Thermocouples, RTDs, Thermistors)
Pressure (e.g., Barometers, Strain Gauges, MEMS Pressure Sensors)
Light (e.g., Photodiodes, LDRs, IR Sensors)
Motion (e.g., Accelerometers, Gyroscopes, PIR Sensors)
Sound (e.g., Microphones, Ultrasonic Sensors)
Gas & Chemical Composition (e.g., Gas Sensors, pH Sensors)

For example, in an air conditioning system, a temperature sensor detects the room’s temperature. The embedded system processes this data and adjusts the cooling settings accordingly. Similarly, in a smartphone, an accelerometer detects movement and rotates the screen based on the phone’s orientation.

What Are the Four Main Types of Sensors?

Sensors come in various types, but they can be categorized into four primary groups based on the type of data they collect.

1. Temperature Sensors

These sensors measure heat levels and are widely used in industrial automation, healthcare, and consumer electronics.

Examples: Thermocouples, Resistance Temperature Detectors (RTDs), and thermistors.
Applications: Air conditioners, refrigerators, and medical devices like digital thermometers.

2. Pressure Sensors

Pressure sensors detect force exerted on a surface and convert it into an electrical signal. They are essential in automotive and industrial applications.

Examples: Strain gauge sensors, piezoelectric sensors, and capacitive pressure sensors.
Applications: Tire pressure monitoring in vehicles, fluid pressure measurement in pipelines.

3. Motion Sensors

Motion sensors detect movement and acceleration. They are used in security systems, gaming controllers, and wearable devices.

Examples: Accelerometers, gyroscopes, and infrared sensors.
Applications: Fitness trackers, anti-theft alarms, and robotic systems.

4. Optical Sensors

Optical sensors detect light intensity and are widely used in smartphones, industrial automation, and medical diagnostics.

Examples: Photodiodes, infrared sensors, and laser sensors.
Applications: Touchscreen devices, barcode scanners, and heart rate monitors.

What Is the Role of Sensors in Embedded Systems?

Sensors act as the eyes and ears of embedded systems. They detect physical changes such as temperature shifts, pressure variations, motion, or light intensity and convert them into signals the system can process. Key functions of sensors in embedded systems including:

Continuous Data Collection: Sensors provide real-time information, helping systems monitor environmental conditions accurately.
Automation and Control: Embedded systems use sensor data to adjust operations without human intervention, improving efficiency.
Safety and Protection: In applications like automotive airbags or fire alarm systems, sensors trigger responses that enhance safety.
Energy Optimization: Smart lighting, climate control, and industrial processes rely on sensors to reduce energy waste.

Without sensors, embedded systems would not be able to interact with their surroundings, making them essential for smart technology.

How Sensors Are Integrated into Embedded Systems?

How to embedded system interact with various sensors? Integrating sensors into embedded systems involves multiple steps, from selecting the right sensor to processing its data for decision-making. Let’s see how they integrated into embedded systems:

1. Selecting the Right Sensor

The first step in sensor integration is choosing the appropriate sensor based on the system’s requirements. Key factors to consider include:

Type of Measurement: Sensors detect parameters like temperature, pressure, motion, or humidity.
Accuracy and Sensitivity: Higher precision is needed in applications like medical devices, while industrial sensors prioritize durability.
Power Consumption: Battery-operated systems require low-power sensors to enhance efficiency.
Communication Interface: Sensors use protocols like I2C, SPI, UART, or analog output to transmit data.

Selecting the right sensor ensures optimal system performance and reliability.

2. Connecting Sensors to the Embedded System

Once the sensor is selected, it needs to be physically connected to the embedded system. The connection type depends on whether the sensor is analog or digital.

Analog Sensors: These sensors provide continuous voltage signals that vary based on detected parameters. An Analog-to-Digital Converter (ADC) is required to process the signal.
Digital Sensors: These sensors transmit data in binary form (0s and 1s) and can be directly connected to microcontrollers using interfaces like I2C, SPI, or UART.

3. Sensor Calibration and Signal Conditioning

Before using sensor data, calibration and signal conditioning are necessary to improve accuracy and reliability. Calibration process is by adjusting sensor readings to match standard measurements. For example, temperature sensors need calibration against a known temperature source.

4. Data Processing in Microcontrollers

In the embedded system, the microcontroller acts as the brain of the embedded system, processing data from sensors and executing predefined tasks.

Raw Data Conversion: If the sensor provides an analog output, the ADC (Analog-to-Digital Converter) converts it into a digital signal for processing.
Data Filtering: Algorithms help remove errors or fluctuations from sensor readings.
Decision-Making: The system processes data and triggers appropriate actions. For example, a temperature sensor in an HVAC system adjusts cooling or heating based on detected temperatures.

5. Communication Between Sensors and Embedded Systems

Embedded systems use communication protocols to exchange data between sensors, microcontrollers, and external devices. Commonly used are:

I2C (Inter-Integrated Circuit): Commonly used for connecting multiple low-speed sensors with minimal wiring.
SPI (Serial Peripheral Interface): Provides faster data transfer, suitable for high-speed applications like industrial automation.
UART (Universal Asynchronous Receiver-Transmitter): Used in GPS modules, wireless communication, and serial interfaces.
Wireless Communication: Some sensors use Wi-Fi, Bluetooth, or Zigbee for remote data transmission, seen in smart home and IoT applications.

What Is the Difference Between an Embedded System and a Microcontroller?

Many people may confused about embedded system and microcontroller, they think they are the two different system. Actually, a microcontroller is just one part of an embedded system. The embedded system includes the microcontroller, sensors, actuators, and other components. Their key differences are listing as below:

Feature	Embedded System	Microcontroller
Definition	A complete system that includes a microcontroller, sensors, and actuators	A small chip that processes data
Components	Sensors, microcontroller, actuators, memory, and power supply	CPU, RAM, ROM, and I/O ports
Function	Performs dedicated tasks like monitoring temperature or controlling motors	Executes instructions and controls peripherals
Examples	Smart home systems, medical monitors, industrial robots	ATmega328, PIC16F877A

How Do Microcontrollers Interact with Sensors and Actuators in an Embedded System?

Microcontrollers serve as the core of embedded systems, handling communication between sensors and actuators. Sensors collect real-world data such as temperature, motion, or pressure and send it to the microcontroller for processing. Based on this data, the microcontroller makes decisions and controls actuators to perform specific actions.

1. Receiving Data from Sensors

Sensors generate signals, either analog or digital, which the microcontroller processes:

Analog Sensors: Provide variable voltage signals that require an Analog-to-Digital Converter (ADC) to convert them into digital values.
Digital Sensors: Directly transmit binary data via communication protocols like I2C, SPI, or UART for faster processing.

2. Processing Sensor Data

The microcontroller processes raw sensor readings using filtering, calibration, and decision-making algorithms. It can also store data for further analysis or send it to external systems via wired or wireless communication.

3. Controlling Actuators

After analyzing sensor data, the microcontroller sends control signals to actuators, which convert electrical signals into physical actions. Common actuators include:

Motors: Used in robotic arms, conveyor belts, and automated vehicles.
Relays: Switch electrical circuits on or off, commonly found in home automation.
Solenoids: Control fluid flow in valves and hydraulic systems.

4. Feedback and Closed-Loop Control

Many embedded systems use a closed-loop control system, where sensors provide continuous feedback to the microcontroller. This ensures precise actuator adjustments based on real-time data. For example, in an HVAC system, a temperature sensor constantly updates the microcontroller, which then adjusts the cooling or heating output.

5. Communication with External Devices

Microcontrollers often transmit sensor and actuator data to external systems using wireless communication protocols like Wi-Fi, Bluetooth, or Zigbee. This is common in IoT applications, where devices send data to cloud platforms for remote monitoring and automation.

Examples of Embedded Systems and Sensor Interactions

Embedded systems are used in various industries, with sensors playing a crucial role in automation, monitoring, and control. Below are some common examples where embedded systems interact with different types of sensors to perform real-world tasks efficiently.

1. Automotive Systems

Wheel speed sensors detect the rotation of each wheel, and the microcontroller adjusts braking pressure to prevent skidding.
Pressure sensors in tires continuously send data to the embedded system, alerting the driver if pressure drops below a safe level.

2. Industrial Automation

Sensors monitor environmental conditions in manufacturing plants to maintain product quality, especially in food processing and pharmaceuticals.
Robots use infrared and ultrasonic sensors to detect objects and avoid collisions while performing automated tasks.

3. Healthcare and Medical Devices

Wearable devices use optical or ECG sensors to track heartbeats and detect irregularities.
Glucose sensors in insulin pumps help diabetic patients regulate blood sugar levels automatically.

4. Smart Home Automation

Infrared sensors detect movement, activating alarms or security cameras in case of intrusion.
Light sensors adjust indoor lighting based on natural daylight levels, reducing energy consumption.

5. Wearable Technology

Sensors measure heart rate, step count, and blood oxygen levels, helping users track fitness goals.
Smart textiles with embedded sensors monitor body temperature and adjust clothing insulation accordingly.

One-Stop PCB & PCBA Manufacturer for Embedded Systems

After understanding how the embedded system interacts with the sensors and finalizing your project design, are you looking for an one-stop PCB manufacturer to make it into reality? If you are doing this, then do not hesitate to contact Best Technology.

Since established in 2006, we have worked in PCB & PCBA for more than 18 years, during these years, we have accumulated much experience to overcome numerous difficulties in the manufacturing. We have our own PCB factories in Shenzhen, including FR4 PCB, metal core PCB, ceramic PCB, flex & rigid flex PCB. And to serve customer better, we built PCBA factory both in China and Vietnam, each has more than 3 SMT lines and equipped with advanced pick and place aseembly machines. In addtion to this, we offer box building assembly service for embedded systems. Providing full turn-key service from PCB design, PCB fabricating, components sourcing, IC programing, pcb assembly, function testing… If you are interested in it, you are welcome to e-mail us at sales@bestpcbs.com. Our team will try their best to help you!

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Circuit Board Repair: How to Repair a Bad Circuit Board?

Thursday, March 27th, 2025

The Importance of Printed Circuit Boards

Nowadays, printed circuit boards (PCBs) are the backbone of modern electronics. They provide a structured way to connect electronic components, so that devices can function efficiently. Whether in household gadgets, medical equipment, industrial machines, or communication systems, PCBs are everywhere.

However, like any other electronic component, PCBs can develop faults over time. When a PCB fails, the entire device may stop working. Instead of replacing the whole unit, repairing the PCB can be a cost-effective solution. Not only does this save money, but it also reduces electronic waste, which is beneficial for the environment. At Best Technology, we not only fabricate PCB, but also offer circuit board repair service. Our repair guys have 10 years experiences in this industry, you just need to send back your failed PCB to us, then our guys can troubleshoot it very quickly.

Circuit Board Repair: How to Repair a Bad Circuit Board?

Why Do Printed Circuit Boards Fail?

PCB can be failed due to several factors, component damage, short circuits, overheating and so on. Here we listing some common failures in our daily life:

1. Physical Damage

Dropping, bending, or mishandling a device can crack the PCB or damage solder joints. Even minor stress on the board can cause fractures in the copper traces, leading to connectivity issues.

2. Moisture and Contamination

PCBs and components on PCBs are sensitive to moisture. Exposure to humidity or water can lead to corrosion, which can destroy metal contacts and traces. Contaminants like dust, dirt, and chemical residues can also cause shorts and malfunctions.

3. Overheating and Poor Heat Dissipation

Electronic components generate heat during operation. If a PCB lacks proper heat management, components can overheat, causing them to degrade or fail. Poor ventilation, blocked cooling fans, or excessive current loads can worsen this issue.

4. Electrical Overload and Power Surges

Power fluctuations can damage a PCB. Sudden voltage spikes from lightning, faulty power supplies, or unstable electrical systems can cause components to burn out. Using surge protectors and voltage regulators helps prevent these problems.

5. Manufacturing Defects

Some PCB failures originate from the manufacturing process. Defective soldering, poor-quality components, or design flaws can lead to malfunctions. So, choosing a reliable PCB and PCBA manufacturer is necessary to ensure the high performance of PCB.

Can Circuit Boards Be Repaired?

Yes, many PCB failures can be fixed with the right expertise and tools. A damaged PCB doesn’t always mean the entire device is beyond repair. Skilled technicians can diagnose issues, replace faulty components, and restore connections to bring the board back to life. But not all failures can be repaired, only in such conditions:

If the damage is limited to a few burnt or broken components.
If the circuit traces are slightly damaged but can be restored.
If the failure is due to poor soldering or loose connections.

So, when is replacement necessary?

If the PCB has multiple layers with extensive damage.
If the cost of repair exceeds the cost of a new board.
If proprietary components are damaged beyond replacement.

For most cases, a professional circuit board repair service can determine whether fixing the board is practical.

How Much Does It Cost to Repair a Circuit Board?

The cost of repairing a circuit board depends on several factors, including the complexity of the board, the extent of damage, the type of components involved, and whether the repair is done professionally or as a DIY project. Below, we’ll break down the cost considerations in detail.

1. Factors Affecting Circuit Board Repair Costs

a) Type and Complexity of the Circuit Board

Simple single-layer PCBs (used in basic electronics) are easier and cheaper to repair.
Multilayer PCBs (found in advanced devices like medical equipment, industrial machines, and automotive electronics) require specialized tools and expertise, increasing costs.

b) Type of Damage

Minor issues (e.g., loose connections, broken traces, or burnt resistors) are inexpensive to fix.
Major failures (e.g., damaged ICs, burned PCB layers, or extensive corrosion) require expensive replacements or rework.

c) Labor and Service Costs

Professional repair services charge based on time, complexity, and technician expertise.
DIY repairs save on labor costs but require proper tools and skills.

d) Tools and Equipment

Basic tools like a soldering iron, multimeter, and flux are affordable.
Advanced tools like an oscilloscope, reflow station, or thermal imaging camera increase costs.

e) Component Replacement Costs

Common components (resistors, capacitors, and diodes) cost a few cents to a few dollars.
Specialized components (microcontrollers, power modules, or custom ICs) can cost $50 or more.

2. Estimated Cost Breakdown for PCB Repair

Repair Type	Professional Repair Cost ($)	If PCB Made in Best Technology
Solder joint rework	20 – 50	Free
Broken trace repair	30 – 100	Free
Resistor/capacitor replacement	20 – 50	Free
IC/microcontroller replacement	50 – 300	Free
Severe burn damage repair	200 – 600	Free
Full PCB rework	300 – 1000+	Free

Circuit Board Repair Tools

If you want to do circuit board repair by yourself, then prepare these tools first:

1. Soldering Iron and Solder

You will use them when reattaching loose connections and replacing components. During the repairing, a temperature-controlled soldering iron can make sure precision without overheating components.

2. Solder Wick

Removing excess solder is necessary when replacing components. A desoldering pump and wick help clean connections properly.

3. Multimeter

This is used to test PCB function after repairing. It can be used to measure voltage, resistance, capacitance and trace continuity (make sure no circuit short or open circuit), helping to identify broken traces or faulty components.

4. Magnification Tools

Some tiny failures can’t be checked by our naked eyes, so a magnifying glass is necessary to inspect small solder joints and identify small cracks or defects on a PCB.

How to Repair a Circuit Board?

Repairing a circuit board requires a systematic approach to diagnose and fix faults. Whether you’re dealing with broken traces, damaged components, or burnt areas, the right tools and techniques ensure a successful repair. Let’s try to repair a failed PCB step by step:

1. Gather circuit board repair tools

Prepare the tools that I mentioned as above. Of course, it is better if you have some other tools like tweezers and a heat gun. A tweezer can help to move the small components and heat gun is used to rework SMD components.

2. Identify the problem (troubleshooting)

Located the issue through visual inspection, where you check for broken traces, burnt areas, or loose components. A continuity test with a multimeter helps identify broken circuits, while component testing ensures resistors, capacitors, and ICs are functioning correctly. If the board is not physically damaged, power it on at safe condition and measure voltage at key points. Here are some 4 common failures and troubleshooting steps:

a) For repairing broken traces, clean the damaged area and scrape off the solder mask around the break firstly. Then use a solder bridge, jumper wire, or copper wire to reconnect the circuit. After soldering, apply a protective solder mask to prevent further damage.

b) When dealing with loose or cold solder joints, reheat the existing solder with a soldering iron and apply fresh solder for a stronger bond. Flux can help achieve a smooth and reliable connection. Inspecting with a magnifying glass ensures there are no solder bridges or weak connections.

c) If a damaged component is found, carefully desolder it using a pump or wick to remove excess solder. Once removed, insert the new component, make sure solder it with correct polarity and alignment. Solder it in place, trim any excess leads, and check for proper connection with a multimeter.

d) For burnt PCB repairs, cut out the charred section if necessary, then reconstruct missing traces using copper tape or jumper wires. Applying epoxy or solder mask reinforces the repair, preventing further deterioration.

3. Testing after repairing

After completing repairs, conduct a final test by visually inspecting the board, checking continuity with a multimeter, and powering it on under normal conditions. Monitor voltage levels and ensure the repaired components function correctly. If the board operates as expected, the repair is successful.

How to Tell If a Circuit Board Is Fried?

It is very easy to check whether my PCB is fried. We can see it by our eyes, because the fried PCB always have a black color in the burnt area. Other abnormal situation also shows your PCB is fried, like traces cracked or broken means short circuit, and the swollen or leaking capacitors is a sign of electrical failure. Carefully check your PCBs if it is out of work suddenly. Here are some functional signs that means your PCB is fired:

Device doesn’t power on – Could be a blown fuse or damaged trace.
Intermittent operation – Loose connections or weak solder joints.
Unusual smell – A burnt smell suggests overheating damage.

Where Can I Get a Circuit Board Repaired?

If you’re searching for circuit board repair near me, working with Best Technology is the best option. We are a 18 years experienced PCB & PCBA manufacturer, we offer one-stop service from PCB layout, schematics, PCB manufacturing, components souring, PCB assembly, box building assembly, IC programming, and circuit board repairing.

We have professional repair guys that specialized to repair and rework PCBAs. We provide fast turnaround service, it means we can minimize downtime with quick repairs and save much money compared to full replacements. If you need repair circuit boards services, Best Technology is your trusted partner.

Tags:circuit board repair, circuit board repair service, circuit board repair tools
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What is Gerber File in PCB? Gerber File Format, Gerber File Extension

Wednesday, March 26th, 2025

What Is a Gerber File?

A Gerber file is the standard file format used for PCB (Printed Circuit Board) manufacturing. It contains all the details needed to create a PCB, including copper traces, solder masks, drill holes, and silkscreen markings. Think of it as a blueprint for circuit boards—without it, manufacturers wouldn’t know how to fabricate your design.

This file format was developed by Gerber Systems Corp and has been widely adopted in the electronics industry. When a PCB designer completes a circuit board layout, they export the design as a Gerber file, which is then sent to the manufacturer for fabrication. Some manufacturers will make the PCBs directly according to this file. But in Best Technology, our engineering team will optimize this gerber file, such as trace width, add fiducial marks to smooth production and improve the utilization rate of raw materials. The file after optimization we called Working Gerber File (WG/WF), and it will be sent to customer for final approval.

What is Gerber File in PCB? Gerber File Format, Gerber File Extension

Why Is a Gerber File Important for PCB Manufacturing?

A Gerber file provides a precise digital blueprint of the circuit board design. Without these files, manufacturers would have no clear instructions on how to fabricate the board, leading to potential misinterpretations or errors. Gerber files are not standard image or single document file but rather a collection of files. Each file represents a different layer of the PCB, such as:

Copper layers (for electrical connections)
Solder mask layers (to protect copper traces)
Silkscreen layers (for text and symbols)
Drill data files (for hole placements)

Without Gerber files, a PCB manufacturer wouldn’t have the necessary layer information for PCB manufacturing.

Gerber File Format

Nowadays, Gerber files exist in two primary formats:

1. RS-274D (Older Version)

Requires an aperture file to define shapes and sizes.
Can cause compatibility issues with modern PCB software.
Still used by some manufacturers, but largely replaced by the newer format.

2. RS-274X (Current Version)

Includes aperture definitions within the file, making it easier to process.
Supports polarity settings, layer information, and additional metadata.
Preferred by most PCB manufacturers because of better accuracy and compatibility.

For engineers and designers, if you’re generating Gerber files for PCB production, it’s best to use the RS-274X gerber file format to avoid errors during fabrication.

Gerber File Extension

Generally, we see a lot of extensions in a gerber file. Each gerber file extension means one layer, indicating which layer it represents. Here are some common extensions and their meanings when I faced during daily workings:

.GTL – Top Copper Layer
.GBL – Bottom Copper Layer
.GML or .G1, G2, etc. – Inner Copper Layers (for multilayer PCBs)
.GTS – Top Solder Mask
.GBS – Bottom Solder Mask
.GTO – Top Silkscreen (component labels, markings, logos)
.GBO – Bottom Silkscreen
.GTP – Top Solder Paste (for stencil printing)
.GBP – Bottom Solder Paste
.DRL – Drill Data (defines hole sizes and locations)
.TXT or .EXCELLON – Drill Tool List (used with .DRL file)
.GM1 – Mechanical Layer (board outline, cutouts, milling)
.GKO – Keep-Out Layer (defines restricted areas for components)
.GM3 – Additional Mechanical Layer (if multiple mechanical layers exist)
.FAB – Fabrication Layer (contains PCB fabrication details)
.DXX – Drill Drawing (used to document drill hole placements, rarely to use)
.NC – NC Drill File (numerical control drilling instructions)

How do I Open a Gerber File?

Since Gerber files are not text or image files, you need special software to open and view them. Many PCB design tools include built-in Gerber viewers.

Popular Gerber Viewers:

Altium Designer – Used by professional PCB designers.
KiCad – Free and open-source.
Gerbv – A lightweight Gerber viewer.
CAM350 – A versatile gerber viewer
Online Gerber Viewers – Available for quick viewing without software installation.

Herein, Best Team will teach you how to open the gerber file by CAM350 step by step:

1. Open the Gerber Files

Launch CAM350 and open the project containing the Gerber files.

2. Import Gerber Files

Click File > Import > Gerber Data and select all the relevant Gerber files for your PCB.

3. Identify the Different Layers

Once the Gerber files are loaded, you’ll see multiple layers in different colors. Each file corresponds to a specific PCB layer, just I mentioned as above. You can import the layer what you want import and import all layers.

4. Analyze the Design Features

Use zoom and pan tools to inspect individual traces and pads.
Toggle layers on or off in the Layer Panel to isolate specific details.
Measure trace widths, pad sizes, and spacing using measurement tools.

How to Convert Gerber to PDF?

Converting Gerber files to PDF is useful for documentation, design review, and sharing with clients or team members who do not have Gerber viewing software. Here are detailed steps to convert gerber to PDF using CAM350:

Import File > Click File > Print or File > Export > PDF.
In the print settings, select PDF as the output format.
Choose whether you want to print single layers or the entire PCB design.
Click Save, and CAM350 will generate a high-resolution PDF file of your Gerber layout.

Setup

Set the parameters before printing, select these points: fit to page > output all data in black (optional) > separate sheets (optional)

2. Verify the PDF Output

Open the PDF file to ensure all details are visible and clear.
If necessary, go back to CAM350, adjust settings, and export again.

Below is the file printed into PDF.

How Do I Download Gerber Files?

To download Gerber files, follow these steps:

In your PCB design software, select the Export Gerber > Gerber Data > Set your file name, layers name, export path > OK button

Here is all the sharing from Best Technology today if you want to know more about gerber files, welcome to contact us, our team are always online to serve you!

Tags:gerber file format, gerber files
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DC and AC Inverters: What You Need to Know

Thursday, March 20th, 2025

DC and AC inverters are essential components in today’s energy systems. Whether you’re harnessing the power of the sun with solar panels, working with backup power solutions, or simply need a way to power your devices, understanding how these inverters work is crucial. This blog breaks down the purpose, advantages, and practical use of DC and AC inverters, helping you make informed decisions based on your needs.

What is a DC and AC Inverter?

Inverters are electrical devices that convert DC (direct current) to AC (alternating current), or vice versa. Typically, DC power comes from sources like batteries or solar panels, while AC is what you use to power most household appliances. A DC to AC inverter is used to convert the DC power into usable AC power. On the other hand, an AC to DC inverter does the reverse, converting AC power into DC to charge batteries or power DC devices.

In simple terms, a DC to AC inverter allows you to use power from sources like batteries or solar panels in everyday devices that require AC power, such as fans, lights, and even refrigerators. Without inverters, it would be challenging to use energy from renewable sources for traditional home appliances.

DC and AC Inverters: What You Need to Know

What is the Purpose of a DC to AC Inverter?

The primary purpose of a DC to AC inverter is to make DC power usable for AC appliances. Whether you’re working with a solar power system or simply need backup power, inverters are the key to making this energy conversion happen. For example, if you’re using a solar panel setup, you typically generate DC power. Since most home appliances run on AC, you need an inverter to convert that energy into a form you can use.

Inverters are essential in off-grid applications, such as in remote areas, where the electricity grid is unavailable. They provide an efficient way to use stored DC power, converting it into AC electricity for devices that would otherwise be useless.

How Does an Inverter Work When There is No Electricity?

When there’s no grid electricity, inverters can still work by drawing power from other sources like batteries or solar panels. This is particularly helpful in off-grid or emergency situations. The inverter takes the DC power from your stored energy and converts it into AC power to keep your appliances running.

For example, if you have a solar power system with a battery backup, and the power goes out, the inverter allows you to keep your appliances on, as long as your batteries have enough charge. In this way, inverters provide an essential role in maintaining power continuity during outages.

DC Inverter AC Advantages and Disadvantages

DC inverters come with several benefits, particularly in renewable energy applications like solar power systems. They are highly energy-efficient and help convert power from DC sources into usable AC power without much loss. This makes them perfect for off-grid living or areas where solar panels are the primary source of energy.

However, there are some drawbacks. DC inverters may have higher upfront costs, and the complexity of conversion can lead to minor energy losses. They also tend to require more maintenance due to the way they manage energy conversion.

On the flip side, AC inverters are generally more efficient in household and industrial settings because AC power is more compatible with most appliances. Their downside lies in the additional energy needed to convert AC power into usable DC energy when dealing with solar systems or battery charging applications.

Despite these differences, both types of inverters have their place, and their advantages often outweigh the disadvantages when used in the right scenarios.

Which is Better: AC Inverter or DC Inverter?

Choosing between an AC and DC inverter depends on your specific needs. AC inverters are more commonly used for residential and industrial applications, as they are designed to power traditional household appliances. They are easy to integrate into existing power systems and typically provide a reliable power source for most needs.

On the other hand, DC inverters are especially useful for renewable energy applications. If you’re installing solar panels or using a battery backup, a DC inverter is the best choice, as it can convert the stored DC power into AC power for your home. They are also more energy-efficient in off-grid situations, where you rely entirely on solar or battery power.

Ultimately, the “better” inverter is the one that fits your particular power needs. If you’re on the grid or need to power AC devices from a DC source, an AC inverter is the way to go. But for renewable energy setups, DC inverters are a better fit.

How Long Will a 12V Battery Last with an Inverter?

The lifespan of a 12V battery when used with an inverter largely depends on the wattage of the devices you’re powering. Inverters typically drain the battery at different rates based on the energy demand of the connected devices. For instance, if you’re running a light or small appliance, the battery can last for several hours. However, larger appliances like refrigerators or air conditioners will drain the battery much faster.

On average, a 12V battery can provide power for anywhere from 3 to 10 hours with an inverter, depending on the load. It’s essential to size your inverter and battery capacity properly to ensure your system works efficiently. By balancing energy use with battery life, you can maximize the performance of your inverter system.

How to Choose a DC AC Inverter?

Choosing the right DC to AC inverter involves considering several factors. First, determine the type of devices you’ll be powering. Consider the total wattage your devices require. Inverters come in various sizes and capacities, so it’s essential to match the inverter’s output with your needs.

Next, consider the efficiency of the inverter. More efficient models will waste less power and give you better performance, especially if you’re using renewable energy sources like solar power. You should also think about the inverter’s durability, features like surge protection, and whether it has any warranties or support.

The inverter’s voltage rating must also align with your power system. For example, in a 12V system, you should choose a 12V DC to AC inverter. Also, remember to check the inverter’s surge capacity, especially if you’re powering devices with a high initial startup load, like motors.

Why PCB is Important in DC and AC Inverters?

PCBs (Printed Circuit Boards) play a crucial role in both DC and AC inverters by providing the necessary connections and support for various electrical components. Inverters rely on PCBs to ensure proper functionality, reliability, and safety. For DC to AC conversion, the PCB helps in routing the signals between critical components like transistors, diodes, and capacitors, ensuring the conversion process runs smoothly.

In both types of inverters, the PCB also helps dissipate heat, manage power efficiently, and prevent potential short circuits. High-quality PCBs are essential for maintaining the long-term durability and performance of inverters, particularly in energy-intensive applications like solar or backup power systems. The design, material quality, and structure of the PCB can directly affect the efficiency and lifespan of the inverter, making it a key component in any inverter system.

With over 18 years of experience in the PCB manufacturing industry, Best Technology is a trusted name in providing high-quality, reliable PCBs for various applications, including inverters. Our expertise and commitment to innovation allow us to create tailored solutions for both residential and industrial energy systems. Whether you’re looking for robust PCBs for solar inverters, backup power solutions, or any other inverter application, Best Technology ensures precision and durability in every product we deliver. For more information about PCB and PCB assembly, pls feel free to contact us at sales@bestpcbs.com.

FAQs

1. What is the main difference between a DC inverter and an AC inverter?

The main difference is that a DC inverter converts direct current (DC) to alternating current (AC), while an AC inverter converts AC to DC.

2. Can an inverter work without a power source?

Yes, inverters can still function when connected to a backup power source, such as a battery or solar panel, even if there’s no grid electricity.

3. How do you size an inverter for your needs?

The inverter should be sized based on the wattage of the devices you want to power. Make sure the inverter’s output matches or exceeds the required load.

4. What are the typical applications of a DC to AC inverter?

DC to AC inverters are typically used in off-grid applications, renewable energy systems, and backup power solutions.

5. Do DC inverters have better energy efficiency than AC inverters?

Yes, DC inverters are generally more energy-efficient in solar and battery-based systems as they convert stored energy directly without much loss.

Tags:dc and ac inverters
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PCB Assembly Manufacturer, Quality-Focused PCBA Service

Tuesday, March 18th, 2025

PCB Assembly plays a crucial role in modern electronics, turning bare circuit boards into functional devices. Without proper assembly, even the most advanced PCB designs cannot perform as expected. Whether for consumer electronics, automotive applications, or aerospace systems, high-quality PCBA ensures reliability and performance. In this guide, we explore everything about PCB assembly, from types and materials to design considerations and industry applications. By the end, you’ll understand why Best Technology is the right partner for your PCB assembly needs.

At Best Technology, we specialize in precision-driven PCB assembly services, offering turnkey PCBA solutions, rigorous quality control, and advanced manufacturing capabilities to meet diverse industry needs. With over 18 years of experience, Best Technology provide cost-effective, high-accuracy printed circuit board assembly solutions tailored to your requirements. Feel free to contact us at sales@bestpcbs.com for any doubts or queries you might have.

PCB Assembly Manufacturer, Quality-Focused PCBA Service

What is a PCB Assembly?

PCB assembly (PCBA) is the process of placing and soldering electronic components onto a printed circuit board (PCB) to create a functional electronic device. The assembly process involves multiple steps, including surface-mount technology (SMT), through-hole technology (THT), soldering, and quality inspections. Unlike a bare PCB, a fully assembled PCB has all the necessary components installed, making it ready for integration into electronic systems.

What Are the Different Types of PCB Assembly?

1. Surface-Mount Technology (SMT) Assembly – The most common assembly method, SMT involves mounting components directly onto the surface of the PCB. It allows for smaller, more compact designs and is ideal for high-density applications.
2. Through-Hole Technology (THT) Assembly – THT involves inserting component leads into pre-drilled holes on the PCB and soldering them in place. It provides strong mechanical connections and is used in applications requiring durability.
3. Mixed Assembly – A combination of SMT and THT, mixed assembly is used when a design requires both surface-mounted and through-hole components.
4. Single-Sided & Double-Sided Assembly – Single-sided assembly involves placing components on one side of the PCB, while double-sided assembly places components on both sides, maximizing space and functionality.
5. Box Build Assembly – This type of assembly goes beyond the PCB level, including wire harnesses, enclosures, and full system integration.
6. Turnkey PCB Assembly – A complete service where the manufacturer handles everything from PCB fabrication to component sourcing, assembly, and testing, providing a ready-to-use product.
7. Prototype PCB Assembly – Used for product development and testing before full-scale production.

What Materials Are Used to Make PCB Assembly?

Several materials are used in PCB assembly to ensure reliability and performance:

PCB Substrate – The base material of the PCB, commonly made from FR4 (fiberglass epoxy), metal core, or ceramic for high-performance applications.
Copper Traces – Thin layers of copper form the conductive pathways for electrical signals.
Solder Mask – A protective layer applied over copper traces to prevent oxidation and short circuits.
Silkscreen Layer – Used for labeling component positions and reference markings.
Solder Paste – A mixture of flux and metal alloy used in SMT assembly to attach components before reflow soldering.
Electronic Components – Resistors, capacitors, ICs, diodes, and other essential parts that enable the PCB to function.
Solder Wire & Flux – Used in THT assembly to create strong electrical connections between components and the PCB.

How to Design PCB Assembly?

Component Placement – Arrange components efficiently to optimize space, signal integrity, and heat dissipation.
Layer Stack-Up – Define the number of PCB layers to meet electrical and mechanical requirements.
Trace Routing – Ensure proper trace width, spacing, and routing strategies to minimize signal interference.
Power & Ground Planes – Design stable power distribution and ground layers for noise reduction.
Thermal Management – Use thermal vias, heat sinks, and copper pours to manage heat dissipation.
DFM (Design for Manufacturability) – Optimize the PCB layout for efficient assembly, reducing potential defects and rework.
DFT (Design for Testing) – Include test points and accessibility for automated testing.
Bill of Materials (BOM) Creation – List all required components, their specifications, and sourcing details.

What Are the Benefits of PCB Assembly?

Compact Design – Enables smaller, lightweight devices with high functionality.
Cost-Effective Production – Automated assembly reduces labor costs and increases efficiency.
High Reliability – Advanced soldering techniques and quality checks ensure long-lasting performance.
Scalability – Suitable for both low-volume prototypes and high-volume manufacturing.
Customization – Supports specialized requirements, such as high-speed, high-frequency, or high-temperature applications.

What Are the Applications of PCB Assembly?

Consumer Electronics – Smartphones, tablets, laptops, and wearable devices.
Automotive – Engine control units, infotainment systems, and safety sensors.
Medical Devices – Patient monitoring systems, diagnostic tools, and imaging equipment.
Aerospace & Defense – Avionics, communication systems, and radar technology.
Industrial Automation – Robotics, control systems, and power electronics.
Telecommunications – Networking equipment, signal processing, and wireless communication devices.

Why Choose Best Technology as Your PCB Assembly Manufacturer?

Experience & Expertise – Over 18 years of experience in PCB manufacturing and PCB assembly. Best Technology is a leading PCB Assembly Manufacturer, providing manufacturing and sale service of various types of printed circuit boards and quality-focused PCBA Service.

Comprehensive Services – Full turnkey, partial turnkey, and consignment assembly options. We provide one-stop service, including PCB assembly and component purchasing and all-around technical support before and after-sales.

Quality Assurance – Stringent IPC and industry-standard testing, including AOI, X-ray, and functional testing. The pursuit of quality and innovation is the driving force of Best Technology. Every stage, from sourcing raw materials to production, inspection, packaging, and even sales and marketing, strictly follows ISO quality standards to ensure consistency and reliability.

Reliable Component Sourcing – Direct partnerships with trusted suppliers to prevent counterfeit parts. We procure all components exclusively from manufacturers or trusted distributors like Digikey, Mouser, Future, TTI, Avnet, and Arrow, ensuring authenticity.

State-of-the-Art Equipment – Advanced assembly machines ensure precision and efficiency. By leveraging cutting-edge technology and advanced PCB assembly equipment, we constantly refine our manufacturing processes, enhance testing and measurement techniques, and optimize our quality management system.

On-Time Delivery – Expedited services available for urgent orders. No matter where you are, we guarantee on-time delivery for every order.

Competitive Pricing – Cost-effective solutions without compromising quality.

Customer Support – Dedicated one-on-one sales assistance for a smooth collaboration. With exceptional team, Best Technology ensures prompt responses within 12 hours.

In conclusion, choosing the right PCB assembly manufacturer ensures product reliability, cost-effectiveness, and timely delivery. Best Technology offers expert solutions for various industries with a focus on quality and efficiency. Whether you need a simple prototype or a high-volume production run, our team is ready to support your project. Just feel free to reach out to us at sales@bestpcbs.com to discuss your PCB assembly needs!

FAQs of PCB Assembly

1. What is the difference between PCB and PCB assembly?

A PCB (Printed Circuit Board) is the bare board with copper traces, while a PCB Assembly (PCBA) includes all the necessary electronic components soldered onto the board, making it a fully functional unit ready for use.

2. What is the purpose of a pick and place drawing in the SMT process?

A pick and place drawing provides detailed guidance for automated SMT machines, specifying component placement, orientation, and reference designators on the PCB. It ensures accurate positioning (including polarity indicators for diodes and capacitors) and facilitates post-assembly inspection.

3. What are counterbores and countersinks?

Counterbore: A cylindrical recess with a flat bottom, designed to allow a screw head to sit flush with the PCB surface. Commonly used with flat-head screws to ensure secure mounting, such as for attaching heatsinks or connectors.
Countersink: A conical recess that matches the angle of a tapered screw head, such as self-tapping screws. Helps create a smooth, low-profile surface, often used when securing PCBs within enclosures.

The key difference is that counterbore provides a level surface by embedding the screw head within the material. Countersink features a tapered design that aligns the screw and evenly distributes stress.

4. How to distinguish the PTH & NPTH?

PTH is PLATING Through Hole, it has copper in the holes inside, which can be conductive. NPTH is Non PLATING Through Hole, which don’t have copper inside the holes. Through holes means through the top and bottom on the PCB, it could be PTH and NPTH.

Tags:PCB Assembly, PCB Assembly manufacturer, PCBA, Printed Circuit Board Assembly, Quality-Focused PCBA Service
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Special PCB Design, Prototype, Special PCB Manufacturer

Tuesday, March 18th, 2025

Special PCB is a customized circuit board designed for unique applications where standard PCBs do not meet the required performance, durability, or environmental conditions. These PCBs are used in industries such as aerospace, medical, telecommunications, and automotive, where factors like heat dissipation, high frequency, and miniaturization are crucial. Whether it’s a high-speed PCB, HDI PCB, or heavy copper PCB, each type serves a specific purpose to enhance electronic performance.

Best Technology excel in providing customer-centric support in PCB industry. The team offers special PCB design optimization, material selection guidance, and manufacturing feasibility analysis to the customers. Whether you need a special PCB prototype or full-scale special PCB manufacturing, just feel free to reach out to us at sales@bestpcbs.com, we work closely with you to meet your exact specifications.

Special PCB Design, Prototype, Assembly, Special PCB Manufacturer

What is Special PCB?

A special PCB is a customized printed circuit board that differs from standard PCBs in design, materials, or functionality. It is engineered to meet specific requirements such as high power handling, extreme temperatures, or unique form factors. These boards ensure stability, reliability, and efficiency in demanding applications.

What Are the Different Types of Special PCBs?

Special PCBs can be classified into three main categories based on their materials, functionality, and structure.

1) Material-Based Special PCBs

These PCBs are defined by the materials used to enhance their performance under specific conditions.

Heavy Copper PCB – Uses thick copper layers (≥3 oz) for high current applications and improved thermal management.

High Tg PCB – Made with high glass transition temperature (Tg) materials to withstand extreme heat and mechanical stress.

2) Function-Based Special PCBs

This category includes PCBs designed for specific electrical or performance characteristics.

High-Speed PCB – Designed with low-loss materials and controlled impedance for fast signal transmission in networking and computing.

Impedance Control PCB – Maintains precise impedance levels for RF, microwave, and high-frequency circuits.

RF Board – Uses low-loss materials to minimize signal interference in wireless communication, radar, and satellite applications.

Bus Bar PCB – Incorporates embedded copper bars for high current carrying capacity in power distribution systems.

3) Structure-Based Special PCBs

These PCBs are categorized based on their physical design and layout innovations.

HDI PCB – Features microvias, fine traces, and multiple layers for compact, high-density applications like smartphones and laptops.

Extra Thin PCB – Ultra-thin boards designed for compact and flexible electronic devices.

IC Substrate – Specialized interconnects used to bridge semiconductor chips with larger PCB assemblies.

What Materials Are Used to Make Special PCBs?

The choice of materials in special PCBs determines their electrical performance, heat resistance, and mechanical durability. Here are the key materials used:

1) FR-4

A fiberglass-reinforced epoxy laminate that offers a balance of cost, durability, and electrical insulation. It is commonly used in High Tg PCBs, HDI PCBs, and Impedance Control PCBs where thermal resistance and signal integrity are crucial.

2) High-Tg FR-4

An advanced version of FR-4 with a higher glass transition temperature (Tg), making it suitable for High Tg PCBs and High-Speed PCBs that operate under extreme thermal conditions.

3) Polyimide

This material provides exceptional thermal stability and flexibility. It is widely used in Extra Thin PCBs and HDI PCBs, where space-saving and durability under heat are essential.

4) PTFE (Teflon)

A low-loss, high-frequency material that is ideal for RF Boards and High-Speed PCBs. Its excellent dielectric properties help maintain signal integrity in wireless and microwave applications.

5) Copper

Heavy Copper PCB – Uses thick copper layers (≥3 oz) to support high current loads and enhance heat dissipation.
Bus Bar PCB – Features embedded copper bars for efficient power distribution in industrial and automotive applications.

6) BT (Bismaleimide Triazine) Epoxy Resin

This material is used in IC Substrates for its excellent electrical insulation, high-temperature resistance, and mechanical strength. It ensures reliable connections in semiconductor packaging.

7) Low-Dk (Low Dielectric Constant) and Low-Df (Low Dissipation Factor) Materials

These are specialized dielectric materials used in Impedance Control PCBs and High-Speed PCBs to reduce signal loss and maintain consistent impedance for high-frequency applications.

How to Design a Special PCB?

1) Define Requirements

Start by determining the electrical, thermal, and mechanical specifications needed for the application.

2) Select Materials

Choose the right substrate, copper thickness, and surface finish based on operating conditions and performance needs.

3) Create a Schematic

Develop a circuit diagram to define component placement and electrical connections.

4) Layout Design

Optimize routing, layer stack-up, and impedance matching to ensure signal integrity and manufacturability.

5) Prototyping & Testing

Before mass production, test a prototype to validate functionality, thermal management, and reliability.

What Are the Benefits of a Special PCB?

1) High Performance

Custom designs ensure superior electrical and thermal efficiency.

2) Enhanced Durability

Robust materials and specialized coatings increase lifespan, even in harsh environments.

3) Miniaturization

Advanced designs, such as HDI and extra thin PCBs, enable compact, lightweight devices.

4) Reduced Signal Loss

Impedance control and RF materials enhance signal integrity, crucial for high-speed and wireless applications.

What Are the Applications of Special PCBs?

1) Aerospace & Defense

Used in satellite systems, avionics, and military-grade electronics that require reliability under extreme conditions.

2) Automotive Electronics

Essential for EV power systems, engine control units, and ADAS (Advanced Driver Assistance Systems).

3) Medical Devices

Supports high-precision diagnostic equipment, wearable health monitors, and implantable devices.

4) Telecommunications

Used in 5G infrastructure, networking hardware, and high-speed data transmission systems.

Why Choose Best Technology as Your Special PCB Manufacturer?

1) Industry Expertise

With 18 years of experience, Best Technology specializes in manufacturing high-quality special PCBs tailored to unique requirements.

2) Multi-Variety PCB Manufacturing

Electronics manufacturers often require diverse PCB types within a single project. Best Technology offers a wide range of special PCBs, including Heavy Copper, Bus Bar, High-Speed, IC Substrate, Impedance Control, Extra Thin, High Tg, HDI, and RF Boards. Our ability to handle multiple PCB types under one roof simplifies the supply chain, reduces lead times, and ensures consistency across different PCB designs.

3) High Quality

Each special PCB undergoes rigorous testing to meet international quality and reliability standards.

4) Custom Solutions

As a leading special PCB manufacturer, we offer complete customization based on your project needs from special PCB design to special PCB assembly. Not only provide top quality requirements of Special Printed circuit Board and PCBA service for the market but also meet customer special customized requests.

Small-Batch Production

At Best Technology, we specialize in low-volume special PCB manufacturing, ensuring that even small orders receive the same level of precision and quality as mass production. This allows customers to test new designs, reduce risks, and accelerate product development.

FAQs Of Special PCB

1. What is the maximum operating temperature for PCBs?
Typically, the working temperature for standard PCB materials is 105-130°C. For high-temperature materials, such as those made with 7316D, the working temperature can reach 150-170°C. However, this material requires a higher MOQ.
2. Is the smallest copper trace width you can do 4mil?
Yes.
3. What PCB material brands do you use?
We use brands like Shengyi, KB, ITTEQ, GDM, and etc.
4. What is the maximum board size you can produce?
The maximum size we can produce is 610mm x 610mm.
5. What is the maximum copper thickness for a PCB?
We can produce a maximum copper thickness of 30oz (1050um).

In conclusion, special PCBs are essential for high-performance, reliable, and efficient electronic applications. Whether you need heavy copper PCBs for power applications or HDI boards for miniaturized devices, selecting the right manufacturer is crucial. Best Technology provides industry-leading expertise, top-notch quality, and tailored solutions to ensure your project’s success. Pls feel free to contact us at sales@bestpcbs.com to get started on your special PCB requirements!

Tags:PCBA, Special PCB, Special PCB Assembly, Special PCB design, Special PCB Manufacturer, Special PCB Prototype, Special Printed circuit Board
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Rigid Flex PCB Design, Prototype&Rigid Flex PCB Manufacturer

Tuesday, March 11th, 2025

The birth and development of FPC (Flexible Printed Circuit) and PCB (Printed Circuit Board) have given rise to a new product called the rigid flex PCB. Therefore, a flexible-rigid combination board is a circuit board that combines a flexible circuit with a rigid circuit through processes such as lamination, according to relevant technical requirements, resulting in a circuit board that possesses both the characteristics of FPC and PCB.

What Is Rigid Flex PCB?

A rigid flex PCB is a composite type of circuit board that combines flexible printed circuit boards (FPC) with rigid printed circuit boards (PCB) through specific processes. It integrates the flexibility of FPC and the rigidity of PCB, possessing both characteristics of FPC and PCB. It can be folded or bent to reduce space occupation and can solder complex components, offering higher stability and reliability.

Best technology focus on high quality rigid-flex PCB design, prototype and manufacturing over 18 years. So we can flexibly handle various emergencies encountered in production based on our rich work experience to achieve fast delivery. Meanwhile, we have our own complete PCB manufacturing industry chain and advanced production machines, so we can control the cost of the entire production process well and provide customers with high-quality products at competitive prices. Please feel free to contact us at sales@bestpcbs.com if you have any request for rigid flex PCB.

Rigid Flex PCB Layer Stackup

1. Basic layered architecture

The stacked structure of the rigid-flexible board achieves functional partitioning through the alternating combination of rigid materials and flexible materials:

‌Outer rigid layer‌: Usually uses FR4 fiberglass board to provide mechanical support and component installation stability, while achieving electrical isolation‌.

‌Intermediate flexible layer‌: It is composed of polyimide (PI) film or polyester (PET), and is combined with rolled & annealed copper or electrolytic copper to form a conductive line to achieve bending connection function‌.

‌Adhesive layer‌: Use thermosetting adhesive (such as epoxy resin) or low-flow adhesive semi-cured sheet to seamlessly combine the rigid layer and the flexible layer to enhance structural stability‌.

Typical example:

Five-layer structure (5-4-1 type): outer rigid board → thermosetting adhesive → inner electrical layer rigid board → thermosetting adhesive → middle signal layer flexible board → thermosetting adhesive → outer rigid board

Four-layer structure: double-layer FPC substrate + gold finger interface + FR4 filling area + hollow layered design, taking into account plug-in stability and flexibility.

2. Material configuration and function

Rigid substrate

FR4 fiberglass board: high temperature resistance, good insulation, thickness 0.2–3.2 mm, used for support and heat dissipation.

Flexible substrate

Polyimide (PI) film: high temperature resistance (>300°C), low deformation, thickness 12.7–127μm, suitable for dynamic bending scenarios.‌

Conductive layer

Rolled copper (smooth and ductile) or electrolytic copper (low cost), thickness 12–35 μm, used for signal transmission.

Protective layer

Coverlay: PI or PET material, thickness 12.7–127 μm, moisture-proof, anti-pollution and solder-resistant.

3. Layer classification and typical application

Single-sided board

Structural features: There is a conductive circuit layer on only one side, and the other side is covered with a substrate or insulating ink, which is transparent under strong light (excluding special process requirements).

Application scenarios: Simple circuit connection scenarios, such as low-complexity sensor modules.

Double-sided board

Structural features: There are conductive circuit layers on both sides, and the electrical connection between layers is achieved through metallized holes (PTH holes).

Application scenarios: General electronic devices, such as basic communication modules.

Multi-layer board

Definition: 3 or more circuit layers are superimposed through a “sandwich” structure, combining rigid substrates with flexible substrates.

Typical layer range: 4, 6, and 8 layers are common, and high-complexity designs can reach 12 or more layers.

Rigid Flex PCB Layer Stackup

What Are the Advantages of Rigid Flex PCB?

Space optimization and lightweight design

Space saving: Through the integrated design of flexible circuits and rigid circuits, the connection requirements of traditional hard boards and flexible boards are reduced, and the space utilization rate is optimized.

Light weight: The weight of flexible materials is only about 10% of that of hard boards, which greatly reduces the overall weight of the equipment.

Shrinkage: Supports three-dimensional folding design, suitable for miniaturized products such as wearable devices and folding screen mobile phones.

Improved reliability

Reduce connection point failures: The integrated structure of the whole board reduces the risk of poor welding or connector failure and improves long-term stability.

Environmental impact resistance: Resistant to high and low temperatures (-55℃~125℃), chemical corrosion and ultraviolet rays, suitable for harsh environments such as automotive electronics and aerospace.

Vibration resistance: The flexible area can absorb mechanical resonance and reduce the impact of vibration and impact on components.

Cost-effectiveness

Reduce assembly costs: Reduce the number of connectors, simplify the production process, and reduce labor and procurement costs.

Reduce maintenance costs: High reliability design extends product life and reduces the frequency of later repairs.

Signal and heat dissipation performance optimization

‌Signal integrity‌: Short transmission path and controlled impedance reduce signal attenuation and support high-speed data transmission (such as industrial camera image processing).

‌EMC performance enhancement‌: The shielding design of the flexible area reduces electromagnetic interference (EMI) and improves the ability to resist radio frequency interference.

‌High heat dissipation efficiency‌: By extending the copper layer area, the heat dissipation path is expanded and the thermal resistance is reduced, which is suitable for high-power equipment.

Structural flexibility and multi-functional integration

‌Dynamic bending design‌: Foldable and curled, adaptable to complex spatial layout (such as laser radar, medical endoscope)

‌High-density wiring‌: HDI technology (blind vias, buried vias) supports multi-layer signal layer and power layer integration to meet complex circuit requirements.

‌Multi-functional adaptation‌: The flexible area and the rigid area are freely combined, compatible with complex component installation and dynamic mechanical structure.

‌Production and design advantages

‌Simplified assembly process‌: Reduce the use of cables and connectors and reduce the assembly error rate.

‌Design freedom‌: Supports three-dimensional wiring and flexibly matches different device forms (such as hearing aids and folding screen hinges.

Through material and process innovation, the rigid-flexible board has achieved breakthroughs in space, reliability, cost and performance, becoming a core solution for high-tech fields such as consumer electronics, automobiles, and medical care.

What Are the Advantages of Rigid Flex PCB?

Rigid-Flex PCB Design Guidelines

1. Preliminary planning and tool configuration

Definition of stack structure:

Use EDA tools such as Altium Designer to define rigid and flexible layers through the stack manager (shortcut D+K), and check the “Is Flex” property to divide the soft and hard areas.

Panel Division and Area Locking:

Use “dividing line” (shortcut D+S) to divide the board surface, fix the rigid area through the 3D lock function, and retain the dynamic bending characteristics of the flexible area.

2. Three-dimensional layout and structural design

3D modeling verification

Enable 3D view in EDA tools, simulate folding paths and bending radii, ensure that the direction of flexible region lines is perpendicular to the bending axis, reduce stress concentration.

It is forbidden to place vias in the dynamic bending area, and the vias should be kept away from the soft and hard combination area ≥ 50mil (high reliability scenarios ≥ 70mil).

Material matching and stacking

The flexible area selects rolled copper (with excellent ductility) as the conductive layer, with a thickness of 12-35μm; the cover film (Coverlay) uses PI material, with a thickness of 12.7-127μm.

The hard plate area is pressed with PP glue (semi-cured sheet) and the flexible plate, and the hollow layered design is used to reduce the bending stress.

3. Routing and through hole design rules

Circuit Optimization

The flexible region conductors use a teardrop transition, with the width maximized (≥4mil), evenly distributed to disperse stress.

Signal lines are preferred to be perpendicular to the bending direction, and multi-layer cross-wiring uses an ‘I-Beam’ structure to enhance fatigue resistance.

Transition Area Treatment

At the junction of rigid and flexible sections, the circuit transitions smoothly to avoid right angles or through-hole (PTH) design; the cover film must have a 0.5–1mm excess for overflow when opening windows.

Stainless steel stiffener strips or PI stiffener films are added on both sides of the bending area to enhance mechanical support.

4. Verification and Production Alignment

Simulation and Test Rules

Verify impedance continuity through TDR testing, with dynamic bending areas requiring more than 100,000 cycles of simulation.

Use tools such as Mentor Xpedition for lamination simulation to check the risk of glue overflow.

Production File Output

Provide layered Gerber files, marking the boundaries of soft and hard regions and the positions of stiffener. CAM engineers need to handle parameters for inner shrinkage due to glue overflow.

Laser cutting parameters for rigid board areas must be precisely controlled in depth to avoid damaging internal layers.

The design of flexible-hard combination boards should combine three-dimensional simulation, material properties, and process limitations, achieving high-density interconnection and reliability balance through layered lamination and dynamic bending rules.

Rigid Flex PCB Manufacturing Process

1. Material preparation and inner layer production

Cutting and drilling

Cutting: Cut the substrate (FR4, PI film, etc.) according to the design parameters, adjust the equipment parameters and clean the surface of the board.

Drilling: Use laser or mechanical drilling technology to make through holes (PTH) or blind holes. The hard board area needs to be cut with controlled depth to avoid damaging the inner layer circuit.

Inner layer circuit formation

Pressure dry film and exposure: Press dry film on the copper clad board, and define the circuit pattern through film alignment exposure.

Development and etching: Develop to remove the unexposed dry film, and the acid etching solution dissolves the unprotected copper layer to form a conductive circuit.

2. Rigid-flexible lamination

Flexible layer processing

Apply cover film: Apply polyimide (PI) cover film to the circuit layer in the flexible area (such as L3/L4), and check bubbles and fitting accuracy after pre-pressing and fixing. ‌

Stiffener and protection‌: Stainless steel stiffener strips or PI reinforcement film are added on both sides of the bending area to improve mechanical strength‌.

‌Multilayer lamination‌

‌Lamination and lamination‌: The flexible board (FPC) and the rigid board (PCB) are alternately laminated through PP glue (semi-cured sheet), and high-temperature lamination is formed into a “sandwich” structure to eliminate the risk of delamination‌.

‌Hollow design‌: The dynamic bending area adopts a hollow layering process to reduce stress concentration‌.

3. ‌Outer layer processing and hole metallization‌

Secondary drilling and hole processing‌

‌Laser cutting‌: The outer layer of the hard board area is exposed to the flexible area through laser uncovering (gong edge), and the cutting depth is controlled to avoid damaging the inner layer circuit‌.

‌Copper deposition and copper plating‌: Chemical copper deposition in the hole is used to achieve conduction, and the outer layer is electroplated with a thickened copper layer (12–35μm) to improve the conductivity reliability‌.

Outer layer circuit production‌

‌Graphic transfer‌: The outer copper clad laminate is exposed, developed, and etched to form surface circuits, and the teardrop-shaped pad design enhances the connection strength‌.

4. ‌Surface treatment and molding‌

‌Solder mask and character printing‌

‌Solder mask (green oil): Print photosensitive solder mask ink to cover non-welding areas and form an insulating protective layer after curing‌.

‌Silk screen text‌: Mark component location, product model and other information‌.

Surface metallization‌

‌Electronic nickel immersion gold (ENIG): Chemical nickel-gold plating in the pad area to prevent oxidation and improve welding performance‌.

Molding and testing‌

‌Edge and punching‌: Cut the shape to remove excess waste and retain the functional area‌.

‌Reliability test‌:

‌Electrical test‌: Verify continuity and impedance continuity‌.

‌Bending test‌: Simulate dynamic bending for more than 100,000 times to detect the risk of breakage or delamination‌.

5. Special process adaptation

High-frequency signal optimization: high-frequency boards (such as Rogers) are combined with blind and buried hole design to reduce signal attenuation.

Automotive grade requirements: pass vibration and high and low temperature cycle tests (-55℃~125℃), and add FR4 reinforcement to the hard board area.

The production of soft and hard boards requires precise control of material matching and process parameters (such as temperature and pressure), and through multi-layer lamination and dynamic bending optimization, it meets the lightweight and reliability requirements of high-density electronic equipment.

Flex Rigid PCB Manufacturer

Best Technology, a flex rigid PCB manufacturer, establish on June 28, 2006, is a Hong Kong registered company, whom focused on FR4 PCB, Flexible PCB, Flex Rigid PCB design, prototype and manufacturing and also provide PCB assembly(PCBA) service.

BEST begin to As a printed circuit board (PCB) vendor in Asia, we are dedicated to be your best partner of advance, high-precision printed circuit boards, such as heavy copper boards, mixed layers, high TG, HDI, high frequency (Rogers, Taconic), impedance controlled board, Metal Core PCB (MCPCB) such as Aluminum PCB, Copper PCB, and so on.

What we provide is not only PCB & MCPCB manufacturing, but also including PCB duplicating, Engineering & process design, components management & sourcing solution, PCB in house assembly & full system integration, surface mounted technology (SMT).

All the PCB & MCPCB are strictly follow the operation procedures stipulated in ISO9001:2000 in respect to material purchasing, product manufacturing, testing, packing, marketing, etc. All the order placed with us is money-refund-guaranteed.

Most of our engineer and operators has more than ten years of experience in PCB industry, so we can produce special such as 20 OZ heavy copper board, 4 layer MCPCB, etc. At the same time, we purchased many advanced, art-of-state machines & devices for PCB manufacturing, checking, to improve the quality of our boards.

Currently our monthly productivity is 260,000 square feet (28,900 square meter), more than 100 different boards will be completed. We can also provide fast delivery service, and urgent boards can be shipped out within 24 hours!

More information welcome to contact us if you’re interested in us.(The email is at the beginning of this blog)

What Is the Difference Between Rigid Flex PCB and Flex PCB?

Differences in materials and structures

‌‌Flex PCB

Substrate‌: Single or double-layer PI or PET film

Single or multi-layer flexible circuit, without rigid support

Usually without stiffener

‌Rigid-flex PCB

Substrate‌: The rigid area uses FR4 or high-frequency plates, the flexible area uses PI film, and is bonded with PP adhesive (semi-cured sheet).

Mixed structure with 3 or more layers, including blind hole/buried hole design, interconnecting rigid and flexible areas

Stainless steel stiffener strips or PI reinforcement film need to be added in the bending area.

Differences in design and manufacturing process‌

‌Flexible PCB Board

Graphic transfer‌: Circuits are formed by dry film exposure and etching, without rigid support structure‌.

‌Surface treatment‌: Cover with PI protective film (Coverlay) to prevent oxidation‌.

Applicable process‌: Single-sided or double-sided circuits, low cost but weak environmental impact resistance‌.

‌Rigid-flex PCB board‌:

Lamination difficulties‌: Precise control of the thickness matching of the rigid-flexible area is required to avoid delamination (such as hollow delamination process).

Hole processing‌: Vias are prohibited in the dynamic bending area, and a smooth circuit design is required in the rigid-flexible transition area.

Special process‌: Laser cutting of the rigid board area to retain the flexible area, copper plating to ensure conduction.

Comparison of performance and application scenarios‌

‌Flexible board

Low mechanical strength, easily damaged by external forces.

High-frequency signals are easily attenuated (affected by bending).

Low cost (suitable for mass production)

Used in consumer electronics (headphones, smart watches).

Rigid-flexible board

High mechanical strength, rigid area provides support, flexible area resists bending fatigue

The rigid area can integrate high-speed signal layer, impedance control is more precise

High cost (complex process, low yield)

Used in high reliability areas (aerospace, automotive radar)

What Are the Applications of Rigid Flex PCB?

The versatility of rigid flex PCBs makes them essential in various industries:

Consumer Electronics-Used in smartphones, foldable devices, and wearables.

Medical Devices-Applied in implants, imaging systems, and diagnostic tools.

Automotive Electronics-Integrated into advanced driver-assistance systems (ADAS) and infotainment.

Aerospace & Defense-Utilized in satellite systems, avionics, and military-grade equipment.

Industrial Equipment-Found in robotics, control systems, and automation devices.

A well-designed rigid flex PCB enhances performance, reliability, and space efficiency in modern electronic applications. Selecting the right manufacturer ensures high-quality production and long-term durability.

‌Conclusion

As an integrated carrier of rigid-flexible synergy, the rigid-flexible board is driving electronic devices to iterate towards higher integration and stronger reliability with its unique structural design and performance advantages. In the industrial and medical fields, the precise design of the rigid-flexible transition zone (such as the hollow layering process) has achieved stable signal transmission and vibration resistance in complex environments for equipment such as endoscopes and vehicle-mounted radars; in the consumer electronics field, the rigid-flexible board has broken through the space limitations of traditional rigid boards with its high-density wiring and dynamic bending characteristics (≥100,000 cycle life) in folding screen hinges and mobile phone camera modules.

From the perspective of technological evolution, the material innovation (such as the combination of high-frequency FR4 and ultra-thin PI film) and process upgrade (laser cutting precision control) of the rigid-flexible board will continue to promote its application in high-frequency and high-speed scenarios, such as 5G millimeter wave communications and autonomous driving sensors. At the same time, it significantly improves the reliability of the system-level package (SiP) by reducing connector solder joints and optimizing the rigid-flexible transition zone line design (teardrop-shaped wires and reinforcement strips).

In the future, with the popularization of wearable devices and IoT terminals, the soft-hard combination board will be more deeply integrated into the design philosophy of “rigid-flexible symbiosis” – the rigid area carries the computing core, and the flexible area achieves form adaptation. Ultimately, in the “soft-hard game” of the electronics industry, it will become the ultimate solution to balance function, cost and reliability.

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