Before the start of a full PCB production, it is important to ensure the PCB’s functionality. PCBs are the foundation of electronics. Therefore, a faulty circuit board will ruin the entire functionality of the electronics. It would be worse to find this fault in several printed circuit boards that have just been manufactured.
Little mistakes and invisible errors can pose a real threat to the performance of the final PCB. Therefore, engineers ask for prototype printed circuit boards before opting for full-scale production. Prototyping a PCB beforehand is the best way to test a design. In this article, we will shed more light on this topic and how it affects your PCB design.
What is a Prototype PCB Assembly?
This is an experimentation process of the final PCB fabrication. Also, it is a pilot stage of PCB production. Also, it ensures a pre-production evaluation of the boards before final production occurs. Therefore, this helps to minimize the potential errors in a PCB design.
Furthermore, this helps manufacturers evaluate the functionality of their proposed PCBs. Also, printed circuit board prototypes function as a reference for future versions of a product. This isn’t a part of the actual PCB manufacturing process. The surface mount and through hole prototype assemblies are crucial.
This analyzes your circuit board design before incorporating it in the final product. Therefore, this PCB assembly serves as a test board to ensure the functionality of your design. Also, it involves assembling the first sample of a PCB. With printed circuit board assembly, you can identify defects and rectify them. This assembly involves fabricating a circuit board to test its functionality.
There are different types of prototypes. They include functional prototype, visual model, proof of concept, and functional prototype. The visual model displays only the physical aspects of a PCB design. Functional prototypes offer an accurate idea of the functionality of the design in standard production. The proof-of-concept prototype displays the concept of your complex designs.
Applications of Prototype PCB Assembly
PCB prototyping is crucial to the design and testing process in the PCB industry. However, there are situations that call for a Prototype circuit board assembly service. Below are the applications of prototypes.
Testing
Prototypes are crucial for any type of testing. You will need prototypes for either environmental tests or quality assurance tests. Quick prototype PCB production ensures you can prepare for third-party testing. The procurement team can also test the SMT components.
Modeling purposes
PCB designers might need a visual representation of the PCB design. Therefore, a prototype is an efficient option in such cases. A prototype designed with basic materials is a perfect solution. Also, you will get a visual representation without incurring expenses on a standard PCB fabrication.
New product production
Prototyping is essential when a PCB project involves a novel function. Therefore, it helps the designer to test the function and the design. Also, this helps to detect errors in the design process. When working with a new project, prototyping helps to ensure the overall performance of your product.
Complex components
It is essential when a PCB project comprises several complex components and structures. Complex structures can be difficult to fix when issues arise. This assembly can help to detect problems early.
Technical Specifications for Prototype PCB Assembly
There are some specifications that help to ensure your prototype’s functionality.
Hole size and vias type
The size of the hole is essential in determining the type and size of vias needed. The buried vias, blind vias, and through-hole vias are available for this prototype.
Prototype quantities
The quantity of your prototype depends on the final product. Complex projects require several prototype boards. However, simple projects require a minimum of one prototype.
Copper details
The copper weight on the outer and inner layer of a prototype is essential. Also, the copper thickness’s tolerance is important. It is ideal to check it. The copper weight on the outer layer can range from 1. 0 and 2.0 ounces. Also, that of the inner layer can range from 0.5 to 1.0 ounce.
Solder mask
Solder masks prevent short-circuiting. Therefore, it is important to choose the right solder mask for your prototype. For PCB prototype, different colors of solder masks are available to choose from.
Material type
The type of material used for a prototype matters. Choose a material that can hold pressure the prototype will likely experience. Also, ensure the material you choose meets certain standards.
Quality Control in Prototype PCB Assembly
Testing is the most crucial aspect of your prototype PCB. It can be very challenging to carry out this aspect. Remember, the ultimate goal of PCB assembly is to ensure quality. Also, testing focuses on three primary areas. These areas include fabrication, computer alignment, and assembly.
Therefore, there are various tests and inspection your prototype PCBs go through:
In-circuit Test (ICT)
In-circuit test checks for any short circuits in the PCB prototype. Also, it verifies the resistance and capacitance of the PCB and component value that ensures proper assembly. A bed of nail tester can help to perform the in-circuit test.
Functional test
This is another type of test that a prototype PCB can undergo. Functional test helps to verify the presence of PCB components. Also, it analyzes the functionality of these PCB components. Examples of this test include solder float test and X-ray inspection. The peel test and time domain reflectometry test also fall under this category.
Assembly test
This test checks the circuit functionality after completing the assembly process. Assembly test can be manual visual inspection or automated optical inspection. Also, the automated optical inspection helps to check the quality of solders.
Bare-board test
This test is usually performed on a free board to confirm proper definition of circuit connection on the PCB. Bare-board test needs a highlighter pen, a multimeter table, and netlist printout. The multimeter table carries out a continuity test.
Prototype PCB Assembly Capabilities
There are several forms of prototype PCB assembly capabilities. Knowing the forms of prototype PCB assembly is crucial in choosing the perfect form.
Surface mount prototype
This form of prototype PCBA doesn’t involve drilling of holes on the circuit board. The components feature SMD that have leads around them. Also, these leads create a connection with the pads on the circuit board. Surface mount prototype helps to reduce overall production cost.
BGA prototype
The ball grid array prototype is a type of surface-mounting packaging. However, BGA uses underside connection which creates more space for connection. This space increases the PCB density and as such results in higher dielectric performance. BGA prototype helps to increase thermal and electrical performance.
Through hole prototype assembly
There are several steps required for designing this prototype PCBA. Through hole prototype PCBA can occur in two ways. These are through-hole and automated through-hole assembly. The automated through-hole prototype PCBA uses machine during production. However, the manual through hole prototype PCB uses human labor during production.
Mixed prototype assembly
This prototype PCBA combines both through-hole mounting and surface mounting. Therefore, it involves using technology to integrate the through-hole and surface mount.
Turnkey assembly
This form of prototype PCBA is relatively new. Here, onshore manufacturing and cloud-based software handle your orders. Here, the manufacturer is in charge of each aspect of your prototype PCBA.
Factors to Consider when Choosing a Prototype PCB Assembly Service
Quality
This is the first factor you should consider when choosing prototype pcb assembly services. You definitely want a high-quality prototype with great functionality. A prototype PCBA should be free of any defects. Ensure your service provider complies with certain PCB standards. Also, you can evaluate the quality of the service you get through the certification of your provider.
Cost
It is an important factor you need to consider. Various service providers design PCB prototype at a varying cost. Therefore, choose a service provider that meets your budget requirement. However, you should never compromise cost for quality.
Expertise
The experience and skill of the service provider you are opting for are important factors to consider. Choose assembly service with long term experience in PCB prototyping. Also, you don’t want to leave your boards in unsafe hands.
Customization option
PCB prototypes aren’t the real PCBs. Therefore, they can experience change before the final fabrication stage. Choose assembly services that can provide PCB prototypes according to your design requirements. The customization option is one of the PCB assembly capabilities of service providers.
Lead time
Lead time is a crucial factor to consider before you order PCB assembly service. The turnaround time is how long it takes your service provider to design a prototype. Also, this factor is crucial since the fabrication process of prototypes is often scheduled. Some prototype assembly services offer fast lead times. You can check out the ordering process of your service provider. Also, you can opt for quick turn prototypes.
Conclusion
When designing a PCB board, you have to ensure your design is perfect and functional. Also, PCB prototypes are the best way to test your PCB designs. There are several benefits of a prototype circuit board assembly. Prototyping might seem like an extra step. However, it is essential in getting rid of possible defects before final production takes place.
