PCB Train is one of the top circuit assembly companies in the UK, with over 65 years of experience assembling and supplying circuit boards. We provide a fast turnaround PCB circuit assembly service where we assemble and despatch within as little as 3 working days after receipt of bare PCB's and complete component kits. Our circuit assembly prices are fully inclusive of all tooling costs, including solder paste stencils. Get prices for a variety of quantities and deliveries using our online PCB assembly quote calculator.
For ease of assembly, the maximum overall size of PCB panel (or pallet) within which smaller circuits are step and repeated, is recommended to be around 300 mm x 200 mm. Larger panels may well reduce handling costs, but over-sized panels cause disproportionate problems of misprinted solder paste, panel bounce during SMD assembly, and management of inspected panels nd are not recommended.
BGA footprint pads must be solder resist dammed to ensure adjacent via holes and tracks do not wick solder away from the solder ball. Do not put via holes in BGA pads....
or indeed in any SMD pads. Via holes should be tented or covered with solder resist especially under BGA's to avoid solder paste wicking. Do not use the PCB Train Express service for designs containing BGA's because this service does not offer a solder resist. All other PCB Train services include a solder resist as standard.
PCBs supplied by clients must incorporate a handling frame. This is a detachable rectangular frame (made from the same material as the PCB) within which the PCB sits. The handling frame is required so that PCBs with an irregular profile readily fit the conveyors of our SMD mounting machines. Handling frames also ensure that components which overhang the edge of the PCB do not interfere with the edge of the conveyors. When PCBs and PCB Train assembly are ordered at the same time, handling frames are automatically added by PCB Train to the PCB fabrication tooling.
A clear and accurate Bill of Materials must be provided. It is invaluable for clarity to include Farnell part numbers. Different types of components should be listed in groups, i.e. 0805 10nf's sequentially, then 0805 100nf's etc. Component values should be clear e.g. 100R, 100K, 100M etc, and not just "100" printed as the value. BOMs must clearly identify parts as either "customer supplied", "PCB Train supplied" or "not fitted". For further advice about submission of your Bill of Materials / assembly data, please click here:
Free standard "R's" AND "C's"
Listed below are the PCB Train assembly components that we supply to you without charge. All other components must be sent to us for assembly.
SMD Capacitors: Package type 0603, or 0805, or 1206
Type: single-layer ceramic or multi-layer, as appropriate for the value. Values: 10pf, 22pf, 27pf, 47pf, 100pf, 220pf, 470pf, 1Nf, 1N2, 2N2, 4N7, 10Nf, 22Nf, 47Nf, 100Nf, 220Nf, 470Nf, 1U
SMD Resistors : Package type 0603, or 0805, or 1206 values: E24
Our assembly prices assume that the panel to be assembled contains a single circuit or a step & repeat of a single circuit. We define a single circuit (for assembly purposes) as that assembly where all the part references in the bill of materials (and on the legend) present in the data are unique. There must be no duplication of part references, e.g. multiple "R1's". We must be supplied with single image Gerber data which we will incorporate into a panel designed by us, suitable for efficient assembly.
Step & repeated panels for assembly should be kept within ......
A maximum size of around 200mm x 300mm, about the size of an A4 sheet of paper.
Many CAD design packages allow different circuits to be merged into the same panel, and create a single set of Gerber data. However, multi-circuit panels created by merging different designs of circuit into a single mother panel create insurmountable assembly problems. There is often insufficient gap between circuits and poor design of break-out tabs make the panels unstable. Part references are duplicated in the BOM and legend. We regret that we are unable to accept orders for the assembly of multi-circuit panels which exhibit these design weaknesses and data errors.
Customer supplied components, commonly called "free issue" parts are not to be confused with the free standard "Rs" and "Cs" which are available from us for any assembly order.
For orders under a batch total of 500 SMD placements, customers may supply (free-issue) discrete SMD parts (non-taped and reeled)....
For orders which exceed a total of 500 SMD placements, the components supplied must be taped and reeled and ICs must be tubed or waffle packed, otherwise our quoted assembly prices will be invalid.
Errors in client supplied kits are the most frequent causes of production delay. Do not trust your component supplier. The component distributor's error rate is over 2%. Do not send us component kits directly from distributors without double checking their accuracy. We may find kit supply errors but we do not warrant that we will. We may not identify wrongly labelled components. An error in a free-issue kit supplied to us is your error. We will fit the parts you supply to us. Rectification costs attributable to wrongly supplied parts are additional to our quoted prices.
Count parts and check that quantities agrees with the BOM, after making due allowance for spares (see below). The identity of each component must be checked against the attached label. Check every digit in the part reference, including the tolerance and voltage rating. Check that the component footprint matches the PCB pads.
You may like to consider the advantages of getting us to supply your components. If we supply kits, we take responsibility for all incoming kitting checks, and we guarantee that the all components will be supplied and fitted exactly as your Bill of Materials. Our buying power may make it more cost effective for us to supply your kit. We will ensure that your selected parts are available through normal distributor channels. Ask us to quote.
Component kits must be supplied with extra (spare) parts to allow for losses and wastage. 5% extra spares are a reasonable guideline for non-passive parts. It is the nature of pick & place machine feeders that parts are wasted at the beginning and end of reels. If we are not supplied with spare parts, we may short ship completed or part-built PCBs.
As a guideline, a 5% minimum quantity of spares should be supplied with continuous tapes and reels subject to the following absolute minimum number of components:
Due to the variations in prices, the above rules are based on low cost parts. We understand that you may not want to supply say - 25 spare 0805 specialist inductors at £3.00 each. In cases like this, please supply as many spares as you reasonably can with any additional bag labelling to indicate high value. We place greater emphasis in caring for expensive small components over cheap penny parts.
Where possible, all SMD components must be supplied taped and reeled. Parts must be supplied in anti-static component bags (generally pink or silver in colour). No static generating materials are permitted on our production floor.
Component packages or bags must be marked as follows:
It is essential to send us component placement data. This data should include:
- CAD x/y coordinate data in .prn, .csv, .xls, or another editable format.
CAD x/y data must contain columns that include:
We need easily machine-readable data with "one reference designator per line", similar to this format:
Ref DegPart No.Other info / footprint etc. C10805100NFCAP0805 X7RC20805100NFCAP0805 X75C30805100NFCAP0805 X75C40805100NFCAP0805 X75C50805100NFCAP0805 X75
The format example below with "multiple reference designators per line" is a problem to machine read accurately, and is to be avoided:
Ref DegsPart No.QtyC1,C2,C3,C4,C50805100NF5
Silkscreen, (legend or component ident) data should already be in our possession within the bare PCB manufacturing data package. If not, send the data to email@example.com. A schematic diagram of your layout will assist us to resolve any ambiguities about component polarity and physical placement.
We will use our best endeavours to place all client supplied parts. Clients have responsibility for supplying a clean kit of parts and for any additional costs arising from client supplied component kit errors. In respect of PCB Train supplied Rs and Cs, where non-standard component values are called for (e.g.123 ohms), we will fit the nearest E24 value such as 120 ohms.
Customer supplied components that do not correctly fit the PCB footprint will either be modified to fit (if economic) or returned unplaced with the assembly. Badly labelled components that cannot be cross-referenced to the parts list will be returned to clients with the assembly. If an unclear drawing and/or placement diagram is supplied, we will attempt to contact you and ask you to clarify the information. Parts with ambiguous placement locations may be left unplaced and returned with the assembly.
We will build your Printed Circuit Boards to standard commercial quality (using specification IPC-A-610 Rev C - Class 1, Acceptability of Electronic Assemblies) as a guideline. If you require a different level of quality (perhaps Class 2, or Class 3) for military, medical or other requirements then ask us to quote.
Whilst every effort is made to ensure that you receive a fully functional electronic assembly, we can inspect PCB assemblies at a visual level only. If a fault is subsequently found as a result of an assembly error then we will rework the assembly without charge.
A no-clean 2% silver loaded solder wire will be used for all hand assembly. The colophony- free flux contained within this wire will leave a slight "white-powdery" inert residue around the solder joints. This is non-corrosive and is acceptable within most commercial applications