The global Printed Circuit Board (PCB) market is projected to reach $120 billion by 2030, fueled by the ever-increasing demand for electronics across industries. However, this demand brings significant challenges for manufacturers, especially in the crucial post-surface mount technology (SMT) processes of PCB assembly automation.
These processes, including inspection, testing, final assembly, and packaging, are essential to delivering high-quality products. Yet, they often rely on manual labor, leading to bottlenecks, errors, and increased costs. In fact, in manual production and picking systems, human error is responsible for around 80% of total product failures. To remain competitive, manufacturers must embrace PCB assembly automation to streamline operations, improve quality, and reduce costs.
Key Challenges in PCB Assembly Post-SMT processes
The post-SMT stage of PCB assembly presents several challenges that can significantly impact production efficiency and product quality. Let’s look closer at those challenges.
The Reshoring/Onshoring Imperative
Beyond labor costs and quality concerns, the complexities of overseas production, including supply chain disruptions and geopolitical factors, have made domestic production increasingly attractive. PCB assembly automation is key to enabling this shift, addressing labor shortages, ensuring quality control, and providing the flexibility needed to adapt to changing market demands.
Labor Costs and Skill Shortages
Manual PCB assembly is labor-intensive, and rising labor costs, coupled with a shortage of skilled workers, make it increasingly difficult for manufacturers to maintain profitability, especially in regions with high labor rates. Labor represents a significant portion of the total production cost for a printed circuit board, typically ranging from 65% to 80%.
Error Rates and Quality Control
Human error is inevitable in manual assembly processes. Misplaced components, incorrect soldering, and other mistakes can lead to costly rework, scrap, and even product recalls. Implementing effective quality control measures in manual processes is both challenging and expensive.
Production Bottlenecks and Throughput Limitations
Manual assembly lines often suffer from bottlenecks, limiting production throughput and hindering flexibility. This makes it difficult to respond quickly to changing market demands or unexpected fluctuations in order volumes.
The Advantages of PCB Assembly Automation
PCB assembly automation offers a compelling solution to the challenges faced in post-SMT processes. By automating repetitive and labor-intensive tasks, manufacturers can significantly improve efficiency, quality, and cost-effectiveness.
Pick and place robots, for instance, can accurately and rapidly place components on PCBs, reducing human error and increasing throughput. Automated inspection systems ensure consistent quality control, minimizing the risk of defective products reaching the market.
PCB assembly automation not only streamlines production but also improves adherence to manufacturing standards like Design for Testing (DFT), Design for Assembly (DFA), and Design for Manufacturing (DFM). An automated assembly line can standardize quality and consistency in a way that multiple manual engineers, each with their own quirks and methodologies, cannot. This standardization is crucial for ensuring that every PCB meets the highest quality standards and performs reliably.
When it comes to scalability, PCB assembly automation is transformatiuonal. If you’re a PCB assembler looking to increase capacity and produce more boards, automation is the answer. An automated line can significantly increase production speed compared to a team of manual engineers, and it does so with a smaller financial and floor space footprint. This allows manufacturers to respond quickly to growing demand without the need for extensive investments in labor and facilities.
PCB assembly automation also reduces labor costs, minimizes material waste, and increases overall efficiency, leading to a significant return on investment. The cost savings can be substantial, as the typical cost of PCB assembly falls within the range of $0.02 to $0.05 per square inch.
Automated systems can also be easily reconfigured to handle different PCB designs and production requirements, providing the flexibility needed to adapt to changing market demands. The ability to quickly switch between products and ramp up production as needed is crucial in today’s electronics industry.
Key Automation Technologies for Post-SMT PCB Assembly
The post-SMT stage of PCB assembly is ripe for automation, and a variety of technologies are available to streamline and optimize these processes.
Pick and Place Robots
While high-speed, high-volume pick and place machines like those from Juki or Europlacer dominate the SMT assembly line, pick and place robots play a crucial role in other stages of PCB assembly automation. They excel in handling components that are too heavy, oddly shaped, or otherwise unsuitable for traditional SMT machines. These robots are equipped with specialized grippers and vision systems that enable them to precisely pick and place components with varying sizes and shapes.
Moreover, pick and place robots are essential for automating the final assembly process, where the PCB is integrated into the finished product or packaging. These robots can insert the PCB into enclosures, attach connectors, and perform other assembly tasks with speed and accuracy. This level of automation significantly reduces the risk of damage to the PCB or other components during assembly, ensuring a high-quality final product.
Automated Dispensing Systems
More than ever, automated dispensing systems are essential for applying various materials with precision and consistency in post-SMT PCB assembly.
- Types Of Dispensing Systems: These include jetting systems, needle dispensing systems, and screw dispensing systems, each with its own advantages for specific applications.
- Applications In Post-Smt Pcb Assembly: Dispensing systems are used to apply adhesives, solder paste, conformal coatings, and other materials required in the assembly process.
Automation ensures precise and consistent dispensing, minimizing material waste and reducing the risk of defects caused by uneven or insufficient material application.
CNC Routing (Depaneling)
In the post-SMT PCB fabrication process, Computer Numerical Control (CNC) routing machines play a crucial role in depaneling PCBs. PCBs are typically manufactured and assembled in large arrays to optimize handling by SMT equipment. After the components are placed, CNC routing is used to precisely separate individual PCBs from these arrays. This automation ensures clean and accurate cuts, minimizing the risk of damage to the PCBs during separation.
The precision of CNC routing machines is further enhanced by their ability to seamlessly integrate with PCB design software. Gerber and DXF files, the same files used for the PCBA process, can be directly imported into the CNC routing machine’s software. This direct transfer of design information eliminates the need for manual programming, reducing the potential for errors and ensuring that each PCB is cut to the exact specifications outlined in the design. The result is a streamlined manufacturing process with reduced lead times and costs.
Soldering Reflow Ovens
Soldering reflow ovens are indispensable in the PCB assembly process, particularly after the precise placement of components by pick and place robots. These ovens are designed to melt the solder paste applied to the PCB, creating strong and reliable electrical connections between the components and the board.
Automation plays a crucial role in optimizing the reflow soldering process. Automated systems precisely control the temperature profile within the oven, ensuring that the solder paste melts uniformly and forms consistent solder joints. This level of precision is essential for achieving high-quality PCB assembly automation and minimizing the risk of soldering defects, such as cold joints or bridging.
Automation also enables real-time monitoring and adjustment of the reflow process, ensuring that each PCB is soldered under optimal conditions. This level of control and consistency is difficult to achieve with manual processes, making automated reflow ovens a critical component of modern PCB assembly automation.
Cooling Buffers
After the solder paste is melted and solidified in the reflow oven, the PCBs need to be cooled down to a safe handling temperature. Cooling buffers provide a controlled environment for this cooling process, ensuring that the PCBs cool down at a gradual and consistent rate. This controlled cooling prevents thermal shock, which can cause components to crack or warp, leading to potential failures in the finished product.
Finished PCB Handling and Inspection
Automation extends to the handling and inspection of finished PCBs, ensuring efficient and accurate quality control throughout the production process.
Automated Pick-and-Place Systems
These systems efficiently transfer finished PCBs between various stages of the assembly process, minimizing handling time and reducing the risk of damage. They’re crucial in automating the movement of PCBs from one workstation to another, ensuring a seamless flow and minimizing the need for manual intervention.
Automated Inspection Systems
Quality control is paramount in PCB assembly, and automated inspection systems play a vital role. Automated optical inspection (AOI) systems scan PCBs for a wide range of defects, including missing or misplaced components, soldering issues, and other irregularities.
Other automated inspection technologies such as In-Circuit Test (ICT), Flying Probe, X-Ray, and Burn-in testing can be integrated into the production line to ensure comprehensive quality control. By detecting defects early in the process, these systems prevent faulty PCBs from progressing to subsequent stages, saving time and resources.
Integration with Conveyor Systems
Efficient material flow is essential for maximizing productivity. Conveyor systems seamlessly integrate with both pick-and-place and inspection systems, ensuring a smooth and continuous movement of PCBs throughout the production line.
While SMT/PCBA processes often use linear belt conveyors, automation can leverage these existing systems or incorporate rotary systems, work cells, or other specialized conveyor configurations to optimize material handling for specific tasks.
Reject Conveyors
In the pursuit of high-quality PCB assembly, reject conveyors play a critical role in maintaining stringent quality standards. These automated systems are designed to identify and divert defective PCBs from the main production line. When an inspection system, such as an AOI machine, detects a flaw in a PCB, the reject conveyor automatically separates the defective board, preventing it from moving further down the line.
Additional Assembly Automation
A range of other automation technologies further enhance post-SMT PCB assembly.
Screen Printers
Automated screen printers are essential for applying solder paste or adhesive onto PCBs before component placement. These machines use a stencil to deposit a precise and uniform layer of material onto the board, ensuring optimal soldering and adhesion. Automation in screen printing not only improves consistency and accuracy but also significantly reduces material waste compared to manual methods.
Magazine Line Unloaders
Magazine line unloaders are automated systems designed to efficiently remove PCBs from magazines or carriers after they’ve been processed, eliminating the need for manual unloading, reducing labor costs and improving throughput. Automated unloaders can handle a wide range of PCB sizes and magazine types, making them a versatile addition to any PCB assembly line.
Robotic Arms
Robotic arms are versatile tools for tasks like component insertion, soldering, and other assembly operations. They offer flexibility and precision, especially for complex or delicate components.
Automated Screw Driving And Fastening Systems
Automate the process of securing PCBs and components with screws and fasteners, improving efficiency and consistency.
Product Assembly and Box Building Automation
Many assembly and packaging tasks after the PCB is completed are still largely manual, resulting in high labor costs and potential for errors. Automation is increasingly being adopted to address these challenges.
Product Assembly Automation
Robotic arms, equipped with specialized tooling, are employed for tasks like component insertion, screwing, adhesive application, and other assembly operations. They deliver precision and repeatability, ensuring consistent product quality while reducing labor costs. Automated systems can handle various assembly tasks, from simple component placements to complex multi-step processes.
Box Building Automation
Automated box building machines are transforming the packaging process. They will form and seal cardboard boxes quickly and accurately, improving efficiency and consistency. They eliminate the need for manual box folding and taping, reducing labor requirements and minimizing the risk of packaging errors.
Conveyor Systems in Assembly and Packaging
Conveyor systems play a crucial role in transporting products and materials throughout the assembly and packaging lines. They control the flow of goods, ensuring that each item moves to the next stage at the right time. That synchronization improves overall efficiency and reduces bottlenecks, leading to faster production cycles and increased throughput.
Packaging, Palletizing, and Labeling Automation
The final stages of PCB assembly, packaging, and labeling, are also being improved through automation.
Robotic Packaging Systems
Robotic packaging systems are essential for automating the packaging of assembled PCBs and finished electronic products. They excel at tasks such as picking and placing products into boxes or trays, applying protective packaging materials, and sealing packages for shipment.
For bare boards, robotic systems can pick and place them into anti-static thermoformed trays, ensuring their safe handling and protection during storage and transportation. At DEVELOP, we not only offer robotic packaging solutions but also specialize in machining the molds for these anti-static thermoformed trays, catering to the specific needs of the electronics industry.
By automating the packaging process, robotic systems ensure consistent and secure packaging, reducing the risk of damage during transit and minimizing the need for manual intervention. This leads to improved efficiency, reduced labor costs, and enhanced product protection throughout the supply chain.
Automated Palletizing Systems
After packaging, palletizing is a critical step in preparing products for shipping and storage. Automated palletizing systems use robotic arms or specialized palletizing machines to efficiently stack boxes or trays onto pallets. These systems optimize pallet loading patterns, ensuring stability and maximizing space utilization. Of course, automating palletizing reduces labor costs, minimizes the risk of injuries associated with manual palletizing, and accelerates the shipping process.
Automated Labeling Machines
Quickly and easily, without errors, apply labels with barcodes, QR codes, product information, and other essential data to PCBs and finished products. Automated labeling ensures accuracy and consistency, improving inventory management, logistics, and traceability throughout the supply chain.
Integration with Inventory Management Systems
Modern packaging and labeling automation systems often integrate with inventory management systems. This integration enhances logistics by automatically updating inventory records as products are packaged and labeled. It also improves order fulfillment by ensuring that the correct products are picked, packed, and shipped to customers.
Material Handling and Logistics
Efficient material handling and logistics are essential for smooth PCB assembly automation.
Conveyor Systems for PCB and Component Movement
Conveyor systems transport PCBs and components between different workstations and processes within the assembly line. They ensure a continuous flow of materials, minimizing manual handling and reducing the risk of damage or delays.
Warehouse Automation for Inventory Management and Order Fulfillment
Automated storage and retrieval systems (AS/RS) and other warehouse automation technologies optimize inventory management and order fulfillment. They simply automate the storage, retrieval, and picking of PCBs, components, and finished products, improving accuracy and speed.
Assessing Your Potential for PCB Assembly Automation
PCB assembly automation requires careful assessment and planning to ensure successful implementation and maximize the return on investment.
Identify Bottlenecks and Time Constraints
Begin by thoroughly analyzing your current post-SMT processes. Identify areas where production slows down, errors frequently occur, or tasks are particularly labor-intensive. These bottlenecks and time constraints are prime candidates for automation. By addressing these pain points, you can significantly improve efficiency and reduce costs.
Evaluating ROI
Calculating the potential return on investment (ROI) for post-SMT automation is essential to justify the investment. Consider factors such as labor costs, throughput, quality improvements, and reduced downtime. Automation can lead to substantial savings by minimizing labor expenses, increasing production volume, reducing scrap and rework, and improving overall equipment effectiveness.
Evaluate Labor Requirements
Assess the skill level and workload of your current workforce. Determine if automation can free up skilled workers for more complex tasks, allowing them to focus on higher-value activities. Plus, consider if automation can allow you to increase production with the same staffing levels or even reduce labor costs by automating repetitive tasks.
Consider Future Production Needs
Always think long-term and evaluate your future production goals and market demands. Will automation be necessary to meet projected growth or introduce new product lines? By aligning your automation strategy with your future plans, you can ensure that your production capabilities remain adaptable and scalable.
Partner with DEVELOP for Your PCB Assembly Automation Needs
While automation allows manufacturers to take control of their PCB assembly processes, sometimes partnering with a trusted expert can be the most efficient and cost-effective solution. At DEVELOP, we not only offer a wide range of automation solutions but also provide comprehensive high-volume PCB assembly services. Our state-of-the-art facilities and experienced team can handle your PCB assembly needs from start to finish, ensuring the highest quality standards and on-time delivery.
Whether you’re looking to automate specific processes or outsource your entire PCB assembly operation, DEVELOP has the expertise and resources to help you achieve your production goals. Contact us today to explore how we can partner with you to streamline your operations and deliver exceptional results.
The Future of PCB Assembly is Automated: Are You Ready?
The advantages of automating post-SMT processes in PCB assembly are undeniable. From pick and place robots ensuring precision and speed to automated optical inspection guaranteeing product quality, automation transforms production lines. By reducing human error, streamlining processes, and boosting throughput, manufacturers can significantly reduce costs, improve quality, and enhance their competitiveness in the global market.
If you’re ready to explore the transformative potential of automation for your PCB assembly line, our free eBook, Automate to Elevate: Your Guide to Automation Assessments, is your essential resource. It provides valuable insights into assessing your facility’s automation readiness and identifying the key areas where automation can make the most significant impact.
Take the next step towards a more efficient, cost-effective, and future-ready PCB assembly line.
Alternatively, take our free Automation Assessment Questionnaire and get an instant snapshot of your potential for automation. The future of PCB assembly is automated, and the time to elevate your production is now.
About the Authors:
Matt Moseman leads as President of DEVELOP, with a strong foundation from the Milwaukee School of Engineering, where he earned both a Bachelor’s and a Master’s in New Product Management. Moseman’s career highlights include his pivotal role in founding NodeUDesign, innovating in automation hardware, and driving DEVELOP LLC to the forefront of industrial robotics with a focus on enhancing productivity and efficiency.
Sean McKittrick, as Project Program Coordinator at DEVELOP LLC, brings a multifaceted background from Knox College. McKittrick’s first year at DEVELOP LLC has been marked by significant team growth and zero turnover, showcasing his ability to build a collaborative and effective work environment. His experience spans quality management in healthcare software to managing production for a million pounds of material monthly, highlighting his diverse expertise in project coordination and manufacturing excellence.