WE BUILD YOUR ELECTRONIC DEVICES
Reliable and highly functional, we partner with you in forming specific work instructions and then link together all of the components and sub-assemblies that go into the production of your product.
Prototypes are pre-production samples that are made to validate that your product works. They often use all types of assembly techniques in proving the concept and production viability. This generally follows the design and development stage.
Prototypes are constructed so that they can be mass-produced. Material and component availability must be sustainable to keep costs down. We use standard operating procedures (SOP) to ensure that your final product will be made to the same high quality and consistency every-time. The availability of materials and components are continuously monitored to prevent delays and on-time delivery.
Once your prototype has been manufactured, we offer recommendations for improvement and possible cost effective changes based on our extensive expertise and experience in providing a smooth transition from prototyping to production.
The typical stages in building a Prototype are:
- Proto Engineering & Documentation
- PCB Procurement
- Component Procurement
- Production – fabrication
- Mechanical prototype assembly
- Quality Control checks
- Recommendations for improvements
- Rebuild of further prototypes if necessary
Printed Circuit Board assembly contains a number of fabrication stages and is essential that they all work together and flow on to form one overall process. Before any production can proceed, all documented work instructions linking each process to the next are set out in a “Standard-Operating-Procedure” (SOP). This correlates all directives and co-ordinates the transition of your product through each work-centre to the next.
Accurate SMD board printing is an important start to the process and that is why we only use stainless steel stencils in our Automatic in-line paste printing machines. Employing state of the art Pick & Place robotics ensures precise placement of all SMD components. Controlled reflow soldering is easily achieved using Vapour Phase techniques. An Automated Optical Inspection (AOI) machine is used for quick and accurate Quality Conformance (QC) checks. This means we are capable of 100% inspection of all components checking for correct polarity, value and integrity of all solder joints. The PCBs are washed to remove excess solder flux and impurities.
We utilise a range of bench-top optical inspection stations, microscopes and benched mounted HD vision systems in our quality control inspection process. For a more in-depth structural evaluation, we use a 100KV. X-ray machine. This allows us to inspect BGA and Micro BGA components, PCB cross-sections, component internal wire connections and structural fractures. With 130 times magnification, a 5-micon focal spot and sophisticated software, we can inspect soldered pad connections and determine the percentage void-to-pad ratio per connection. Customised reports are available on request.
We can provide a “Chip-On-Board” (COB) epoxy encapsulation service wherein individual components can be epoxy coated and anchored to the PCB for rigidity and strength, or for masking purposes in the protection of your “Intellectual Property” (IP). An acrylic Conformal Coating service can be provided to protect PCBs used in corrosive, humid or hazardous gas environments. Other optional services provided include; the mechanical installation of PCBs to enclosures, fitting of heatsinks, Pemserts, spacers and mounting hardware.
The typical stages for PCB assembly in Production are:
- Production Engineering & Planning
- Work order and SOP Instructions created
- BOM check
- SOP verification
- Component Bake-out
- SMD Pick and Place loading
- AOI Inspection (QC1)
- X-Ray Inspection (optional)
- THD Component loading
- PCB Washing
- Enhanced Vision Inspection (QC2)
- Programming Microprocessors
- HD Vision inspection (QC3)
- X-Ray Inspection (optional)
- Epoxy Encapsulation of parts COB (optional)
- Conformal Coating (optional)
- Mechanical assembly (optional)
- SOP documentation update
- Packaging for delivery
Mechanical assembly is the process of putting the manufactured parts together to form your product. It is an important part of electronic manufacturing and getting it right is critical to your success. We follow detailed work instructions and employ specific engineering techniques to ensure a cost effective and on-time solution.
We have a fully kitted in-house mechanical workshop to produce customised tooling, jigs and production assembly aids. This allows us to react quickly to any online production requirement needed in meeting our delivery deadlines. Conformal coatings can be applied to assemblies to prevent moisture ingress if required. They are available in Acrylic or Polyurethane and each having their own Pros & Cons. We are ready to advise you on the best option for your application.
We have an Automated Epoxy Encapsulation machine (COB) that can dispense Epoxies over sensitive areas of assemblies and is often useful in IP protection. This can also be used to anchor fragile or vibration-sensitive components in your assembly. Our Pemserter machine has the capability of inserting, anchor nuts, spacers and stand-off to both PCBs and Metal fabrications. Programming of on-board Microprocessors with your firmware is also a service we provide. Testing product with your jigs or simply power-up test procedure(s) is readily available. Our capabilities cater for the simple mechanical tasks, for example; mounting of heatsinks onto PCB’s up to the full scale assembly of instrumentation rack systems.