What is the best PCB assembly method for your project?

While through-hole soldered connections do provide some degree of mechanical support, their main purpose is to ensure a reliable electrical connection. The mechanical strength of a solder joint is generally lower compared to other methods of mechanical bonding, such as potting, gluing, or mechanical fasteners (screws, bolts, etc.).

Through-hole assembly has several advantages. It provides mechanical strength, making it suitable for components subjected to stress. It's also easier for manual soldering and repairs, making it a preferred choice for prototyping and small-scale production. Additionally, through-hole components often have better heat dissipation.

Being the oldest and most reliable method of PCB assembly, the Through-hole process entails drilling holes in the circuit board and inserting the leads of electronic components through these holes. Once inserted, the leads are soldered to the opposite side of the board, providing a secure and robust connection. This method is particularly effective for components requiring mechanical stability or generating significant heat during operation. While surface mount technology has gained popularity for its compactness, through-hole assembly remains preferred for applications where durability and resilience are paramount. Thus, the time-tested through-hole method is a vital option in electronic manufacturing.

Selecting the best PCB assembly method for your project depends on factors such as design complexity, production volume, and cost considerations. For small-scale productions or prototypes, hand soldering may suffice, offering flexibility and cost-effectiveness. Larger volumes often benefit from automated surface mount technology (SMT) assembly, ensuring precision and efficiency. Through-hole assembly is suitable for projects requiring robust mechanical connections. Advanced technologies like mixed assembly methods provide a hybrid approach, combining the strengths of SMT and through-hole techniques.

TH assembly is beneficial when working with high-power components, as this provides a solid connection to all the layers of the PCBs TH components are also easier for inhouse prototyping but take more PCB real estate

The advantage of SMT is a mechanized and automated assembly of components, which reduces human errors and gives faster turn key times

A surface-mount assembly predominantly involves electronic components mounted directly onto the surface of the PCB, eliminating the need for traditional through-hole components. It is the most common approach due to its compact design, allowing for smaller, lighter electronic devices. This modern method enhances the efficiency of the assembly process, as components are placed using automated machines, increasing precision and speed. Surface-mount technology facilitates the creation of more densely populated PCBs, accommodating the trend towards miniaturisation in electronic devices. The widespread adoption of surface-mount assembly has made it an industry standard, contributing to producing advanced and compact electronic products.

This is a well-written explanation of surface-mount assembly highlighting its many advantages. For these and other reasons, be sure to utilize a knowledgeable electronics manufacturer with quality certifications.

Surface-mount assembly offers advantages in terms of size, weight, and manufacturing efficiency. It allows for smaller and more compact designs, making it ideal for miniaturized electronics. Surface-mount components are usually cheaper, and automated assembly processes can handle large production volumes efficiently. This method is often preferred for modern, high-density electronic devices.

Mixed assembly combines through-hole and surface-mount techniques while integrating components with different form factors and mounting styles on the same printed circuit board (PCB). Through-hole components are inserted into holes on the PCB and soldered on one side, while surface-mount components are attached directly to the board's surface. Mixed assembly is often employed when specific components, such as connectors or specialised sensors, are better suited for through-hole mounting. In contrast, others benefit from the space-saving advantages of surface-mount technology. This approach optimises the assembly process, allowing for the best combination of component types based on functionality and design requirements.

Like every other PCB question, the answer is, it depends. but power electronics application where operation are at 3kW I generally prefer going with THT components For small boards and mixed-signal designs I prefer going with SMT components.

Consider factors like project size, component availability, production volume, and budget. If space and weight are critical, surface-mount might be suitable. For prototyping and durability, through-hole could be better. Evaluate the assembly complexity and whether automated production aligns with your needs. Ultimately, it's a balance based on your project's specific requirements and constraints.

Talk to your manufacturer, and ask them what are their capabilities for assembly and set your DRC check as per that, it will save you tons of cost and time.

Different devices require different components. The choice between a surface mount device and a through hole one is basically dependent on availability, aesthetics and the form factor you are looking to achieve with the design. The electrical capabilities of an SMD vs a THT device might be exactly the same. Therefore if you are looking to do the assembly yourself and don't have a professional set up then THT would be easier to hand solder or 0805 SMD components. For DFM(Design for Manufacture) then it will depend on your manufacturer's capabilities.

Overall, educating customers about PCB assembly is a win-win situation, as it leads to better collaboration, higher-quality products, cost-effective solutions, and improved customer satisfaction. It invests in a successful partnership between customers and PCB assembly service providers. Also, you might like to understand the PCB assembly process further while considering electronics manufacturers. Search for "ANZERs to understanding printed circuit board assembly" to gain more insight.

For high voltage designs where a large voltage drop is needed (kilovolts) - to prevent creepage effects - THT is preferable over SMT components if there are particular space constraints. This is one of a few scenarios where using THT saves board space. Assuming 'Mixed assembly' is allowed.