PCB Assembly: Through-Hole & SMT
At Active-PCB Solutions, we provide both through-hole and Surface Mount Technology (SMT) assembly as part of our comprehensive PCB manufacturing services. From our Reading facility, we manufacture complex electronic assemblies for UK OEMs, combining automated production equipment with experienced technicians and established quality control processes.
Our through-hole assembly capabilities include flow soldering, selective soldering and precision hand soldering, supporting components that require robust mechanical connections or specialist assembly processes. For compact, high-density PCB designs, our automated SMT production lines provide accurate component placement and repeatable soldering processes. By combining both technologies, we can accommodate mixed-technology assemblies for demanding applications, supported by in-house inspection and testing.
Through-Hole Assembly | Active-PCB Solutions
Plated Through-Hole (PTH) assembly involves inserting component leads through holes in a printed circuit board and soldering them to create electrical and mechanical connections. This technique is particularly suitable for connectors, larger components and applications requiring additional mechanical strength.
At Active-PCB Solutions, our through-hole assembly capabilities include flow soldering, selective soldering and precision hand soldering. These processes allow us to accommodate a wide range of component types and assembly requirements, including mixed-technology PCB designs.
Our experienced production team combines automated equipment with specialist soldering techniques to support consistent workmanship and quality throughout the manufacturing process.
Benefits of Through-Hole Assembly
- Strength and Durability: Through-hole connections provide strong mechanical support, making them particularly suitable for connectors, larger components and assemblies exposed to vibration or mechanical stress.
- Prototyping and Testing: Through-hole components can be easier to handle, replace and modify during prototype development, making them useful for design validation and testing.
- High-Power Applications: Certain through-hole components are well suited to applications involving higher currents or greater power dissipation, depending on component design and thermal requirements.
- Specialist Component Assembly: Precision hand soldering allows components unsuitable for standard automated soldering processes, including certain heat-sensitive components, to be assembled under controlled conditions.
Drawbacks of Through-Hole Assembly:
- Space and Weight Limitations: Through-hole assembly is bulkier, with components protruding through the PCB, which may not be suitable for high-density, compact designs.
- Slower Assembly Time: The additional drilling and manual or wave soldering required make this a more time-consuming and costly process, especially for high-volume production.
Surface Mount Technology (SMT) | Active-PCB Solutions
Surface Mount Technology (SMT) is a more modern PCB assembly method in which components are placed directly onto the PCB surface without the need for holes. SMT allows for smaller, lighter, and more complex assemblies, making it ideal for high-density designs, particularly in consumer electronics and telecommunications.
Our advanced SMT assembly capabilities are supported by Juki placement machines, DEK screen printers and BTU reflow ovens, enabling accurate component placement and consistent soldering processes. We accommodate complex, high-density PCB designs incorporating components such as 01005 packages, BGAs, QFNs and flip-chip devices. Our flexible manufacturing approach supports everything from prototyping to ongoing production, with processes tailored to the technical and volume requirements of each project.
Benefits of SMT:
- Compact and Lightweight: Surface Mount Technology components are much smaller, which allows for greater component density and enables lightweight, more compact device designs.
- Faster Assembly Process: SMT utilises automated equipment to place and solder components, resulting in higher production speed and efficiency, particularly beneficial for large-scale production.
- Automated Optical Inspection: PCB assemblies can be inspected using our advanced Automated Optical Inspection (AOI) equipment to identify potential component placement and soldering defects. This helps our production team detect issues, investigate their causes and make necessary process adjustments, supporting consistent manufacturing quality and reducing rework.
- Design Flexibility: The smaller size and versatility of SMT components allow engineers to achieve complex circuit designs on limited board space.
Drawbacks of SMT:
- Mechanical Strength: Surface-mounted components rely on solder joints for their attachment to the PCB. For components exposed to significant mechanical stress, such as frequently used connectors, through-hole mounting may provide additional mechanical support.
- Thermal and Power Considerations: Some high-power applications require specialist component packages, thermal management or additional cooling. The suitability of SMT depends on the component design, electrical requirements and operating conditions.
- Heat-Sensitive Components: Certain components, including some batteries and temperature-sensitive devices, cannot withstand standard reflow soldering temperatures. These may require alternative assembly methods or controlled soldering processes.
Comparing Through-Hole Assembly and SMT
When choosing between through-hole assembly and SMT for assembling printed circuit boards, it’s important to consider the intended application, design requirements, and production volume.
Whereas pin through-hole assembly offers durability and reliability, particularly for devices subjected to high mechanical stress or extreme conditions, for compact, lightweight designs that demand higher circuit complexity and production speed, SMT is the preferred choice due to its space-saving and automation-friendly properties.
In most modern PCB assemblies, a combination of PTH and SMT assemblies will be used to achieve a flawless printed circuit board.
Many complex PCB assemblies use a combination of through-hole and Surface Mount Technology (SMT) components. This mixed-technology approach allows manufacturers to take advantage of SMT’s compact, high-density design capabilities while using through-hole assembly where additional mechanical strength or specialist component mounting is required.