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Consumer Electronics PCB – Powering a variety of products!

Consumer Electronics

In today’s era, the need for consumer electronics PCB assembly is growing faster than the global population. All types of consumer electronic devices are made to perform our daily task faster and easy. As a consumer PCB manufacturer, we manufacture consumer electronics PCB which can be used in a wide range of modern consumer electronic devices. We manufacture high quality PCBs by following IPC class 3, RoHS and ISO certifications and regulatory standards which is important for many consumer electronics OEMs.

From your television to your coffee maker, there is no dearth of electronic products that use PCBs. In fact, both businesses and homes simply cannot function without reliable PCBs.

While consumer PCBs are certainly nothing new, the applications for PCBs for electronics and the material used to make them have evolved over a period of time. This is inevitable, especially on account of the growing trend of miniaturization. Also, modern electronics and computer applications require PCBs with high thermal conductivity so that the heat generated can be dissipated. You also need different PCBs for the many kinds of appliances in use. For example, the PCB needed to power a smartwatch is different from the PCB required for a computer.

At GOPCBA, we have over 40 years of experience in crafting a wide variety of PCBs. Whether you need a PCB for a smart home device, a portable electronic or a gaming accessory, we have covered you. We are capable of understanding client requirements and can design PCBs accordingly to exceed customer expectations. We support all types of PCBs, including Rigid-flex PCB and can provide you the suggestions for the right type of PCBs for your industry. Right from design to box build services, our expert professionals have the requisite experience to offer you the best.

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Why us for consumer electronics PCB

State-of-the-art facility

At GOPCBA, we have the necessary technology to ensure we deliver the most complex PCBs. Besides our team of experts is equipped with the industry best practices right from design to assembly.

Stringent Manufacturing Processes

In our quest to offer reliable PCBs for consumer electronics, we ensure that we adhere to industry standards and best practices. Our robust testing protocols ensure there isn’t room for any error.

Quick turnaround time

Quick go-to-market is a big source of advantage in the highly competitive consumer electronics industry. To this end, we offer quick turnaround times that enable you to launch your product that much faster.

No volume constraints

With GOPCBA, you do not have to worry about the volumesof PCB that you require. From prototype quantities to large production runs we have you covered.

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As a leading printed circuit board (PCB) assembly supplier, GOPCBA offers full-service PCB assembly, from consigned manufacturing to complete turnkey solutions. Our services include material procurement, assembly, testing, system integration, inspection, and advanced technologies.

Consumer Electronics PCB Manufacturing Process

The various stages of PCB manufacturing span:

1. Electronics PCB Design and Output

To begin with, a PCB layer is created using a PCB design software by designers. Once the design is approved for production, the design is exported into a supportive format. A Design for Manufacturability test is run to ensure that the design fulfills the requirements for minimum tolerances. What follows next is the PCB printing process.

2. Printing the inner layers

The film is next printed onto a copper foil. The basic form of PCB is a laminate board whose core material is epoxy resin and glass fiber. The laminate serves as an ideal body for receiving the copper. The substrate material provides a sturdy and dust-resistant starting point for the PCB. Copper is pre-bonded on both sides. The process involves whittling away the copper to reveal the design from the films.

3. The copper

sided laminate is cleaned and the clean panel receives the photo resist layer, which hardens after exposure to UV light. The light passes through the clear parts of the film, hardening the photo resist on the copper underneath. The areas not meant to harden are then slated for removal.

4. Removing the Unwanted Copper

A powerful chemical preparation is used to eat away the excess copper. While the exposed copper is removed, the desired copper remains protected beneath the layer of photo resist.

5. Layer Alignment and Optical Inspection

The inner layers are now aligned to the outer ones. With the help of an optical punch, holes are accurately punched. An Automatic Optical Inspection is carried out to ensure absence of defects. Once the stage of inspection is passed, the PCB moves to the final stages of production.

6. Layer-up and Bond

All the layers are now fused. A prepreg layer is placed over the alignment basin. The substrate layer fits over the prepreg before placing the copper sheet. More sheets of prepreg sit on top of the copper layer. Finally, an aluminum foil and copper press plate complete the stack. Now it’s prepped for pressing.

7. Drill

Holes are now are bored into the stack board. An x-ray locator identifies the drill target spots.

8. Plating and Copper Deposition

After drilling, the panel moves onto plating. The process fuses the different layers together using chemical deposition. After a thorough cleaning, the panel undergoes a series of chemical baths.

9. Outer Layer Imaging

Photo resist is once again applied and exposed to UV light. Finally, the outer plates undergo inspection to ensure all of the undesired photo resist was removed.

10. Plating

The panel is electroplated with a thin copper layer. Etching removes the unwanted copper foil from the panel.

11. Final Etching

The unwanted copper undergoes removal. The tin protects the copper during this stage.

12. Solder Mask Application

Panels are cleaned and solder mask applied to both sides and exposed to UV light. The covered portion remains unhardened and undergoes removal.

13. Surface Finish

The appropriate surface finish is added based on bespoke requirements and based on the environment under which the electronic product has to operate. At GOPCBA, we have a wide range of surface finishes on offer.

14. Silkscreen

The vital information pertaining to the PCB is next written on the surface.

15. Electrical Testing

Electrical tests are next performed to check functionality. At GOPCBA, we also perform the Flying Probe Test to test the electrical performance.

16. Profiling and V-Scoring

Printed Circuit Boards are now cut from the original panel. This is done using a Router or V-Groove.

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High Volume PCB Testing Capabilities

GOPCBA has experienced and skilled experts who strive to ensure boards irrespective of their size and volume, have been rigorously tested for quality at every stage of the manufacturing. To maximize quality assurance of large batch PCB assemblies, we perform extensive testing and inspections on all the PCBs irrespective of the volume. We follow a strict quality control process till the boards are shipped out.

We have great proficiency in high volume PCBs and create matchless PCB designs with zero to the minimal margin of error. We make sure all these boards work uniformly. To maximize the quality of these large batch products, we perform extensive testing of all the products. Our expert engineering team leaves no room for improvement after finalizing the product.

We are an ISO 9001:2015 certified company and for the pursuit of the highest PCB quality, we procure parts from authorized vendors. We focus on the components sourcing process as it is the key to maintain production quality. We ensure full traceability and also try to prevent any component failure issues.

Below are the tests we conduct –

A design for manufacturability (DFM) – To make sure your design is suitable for high volume PCB manufacturing
DFA checks – For detecting issues that negatively impact the PCB fabrication process
AOI and AXI tests – Before packaging and shipping
Custom function tests – As needed
Electrical Testing – For confirming the PCB functionality to its original design
Flying Probe Testing – To test electrical performance
Functional Testing – To make sure everything is working as per the specific requirements
In-Circuit Testing
X-ray Testing
Solder Paste Inspection

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High Volume PCB Assembly Technologies

We follow three methods to construct high volume PCB assemblies

Surface Mount Assembly – Through the SMT technique, we achieve miniaturization capabilities and build PCBs with high mechanical strength. For over 40 years, we have been providing SMT PCB assembly services and are totally equipped for ensuring optimal performance even in the shakiest or challenging conditions. Our competitive advantage is based on state-of-the-art technology and a competent team of engineers assures you of quick turnaround times, highest quality standards, and take the entire hassle away from you.
Through-hole Technology – We provide end-to-end through-hole PCB assembly services right from prototype to production. We are fully equipped and competent to handle double wave flow solder services, RoHS soldering, manual & automated component placement, and testing of your boards. High-end technology solutions will be delivered with international quality standards in the lowest turnaround times. We provide both manual and automated techniques and offer complete reliability, high quality PCB at optimal costs, and minimal turnaround times.
Mixed – We render Mixed PCB assembly services by effectively going for Surface Mount Technology (SMT) as well as Through-hole technique and use them with an optimal blend of both of these.

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What is high volume PCB assembly?

High volume PCB Assembly refers to bulk printed circuit board assembly projects of 10,000 pieces or more, in one cycle of production with DFM and DFT. This is highly popular in high-end modern electronic manufacturing companies.

What are the benefits of high volume PCB assembly services?

The benefits of high volume PCB Assembly are

One-time design and prototyping services
Faster time-to-market
cost-efficient as you can purchase in bulk
Consistent quality
Production uniformity
Shortened production cycles

What are the things to consider while choosing high volume PCB Assembly services?

Choosing a high volume PCB manufacturing company is quite a daunting task in this cut-throat competitive space. Two of the most common things one looks for in any company are quality and cost-effectiveness. Besides, you can also look into their experience, manufacturing capabilities, turnaround time, responsiveness, value for time & money, flexibility, and customization options.

Why should I choose Mer-Mar Electronics for high volume PCB assembly services?

Mer-Mar Electronics is a USA-based PCB fabrication and manufacturing company with over 4 decades of experience in PCB assembly services. We are an ISO-certified and ITAR-compliant company. We offer high volume circuit boards in the least turn-around time, flexible shipment plans, and at competitive prices. We follow a client-centric approach to ensure guaranteed quality satisfaction.

How do I get started?

You can send your Gerber files and BOM to us We would provide you the quote Give your confirmation and the order We start with PCB fabrication component procurement We perform soldering and testing Finally, we go for packaging and shipping to you.

What is the high volume PCB Assembly lead time?

Well, we can accurately present the time based on the complexity of your board. Let us first go through your Bill of Materials (BOM) and Gerber files. See how much time it takes.

Can you perform an X-ray inspection after assembly?

Yes, we do. After the PCB assembly, we can launch an x-ray test on your components. The additional charges will be levied after the assembly test.

Will you perform rework if we face any problems with the boards?

We make sure you face zero issues. However, if unfortunately, you face any problems with the boards, please send high-resolution images for proper evaluation. If we get a confirmation of the root cause, we will take responsibility for your board repairs.

How much do you charge for the high volume PCB Assembly process?

As part of the high volume production process, we provide components and parts procurement for optimizing the manufacturing process at zero price. Also, repeat customers may also take advantage of loyalty discounts to reduce the long-term costs of production. Depending on your requirements, we would let you know the final costs.

Do you offer customer support for high batch PCB assembly?

Yes. We do offer reliable customer support for your orders from start to finish. We will walk you through every step of the process and our PCB experts will also be available all the time.