If you’re considering switching an existing electronic product design from through-hole technology to surface mount technology (SMT), you’ll want to do your homework first.
SMT versions of through-hole PCB designs are available in most cases -- and there is no shortage of advantages of surface mount technology. However, failure to account for typical challenges in transitioning to SMT can lead to costly hurdles.
The following steps are meant to serve as a checklist of sorts for your transition. Once you check your boxes, you can move forward with confidence and make informed choices.
Taking Advantage of Surface Mount Technology: 8 Electronic Product Design Tips
1. Make Sure Transition Is Actually a Good Idea
When you look at surface mount vs. through-hole, you will see there are many advantages of surface mount technology, including:
- Lower manufacturing costs. Once you get your SMT design up and running, you can expect to pay less for the cost of building your product. SMT is the go-to now for several reasons, and lower cost is one of those reasons.
- Uses less space. With a few possible exceptions, all the boards in your small mobile devices are SMT. Companies choose SMT because it takes up less space, which allows them to deliver more with less bulk.
- Faster manufacturing. What may take a few hours on a through-hole board can take five minutes on an SMT board.
However, there are a few reasons why you might want to stick with through-hole, including:
- Durability. For applications where the part will be subjected to serious impacts, through-hole will hold up better.
- Power. Many mobile devices will still use through-hole for power ports because the connections transfer power more efficiently.
Keep in mind that some components may need to remain through-hole even if you do transition to SMT for durability and power.
2. Regulatory Certifications
There are a few things you should keep in mind with your PCB development plan to minimize issues with regulatory certifications:
- Allow as many deviations for component selection as you can. You may need to make changes to meet regulations.
- Determine the impact of the redesign on regulations. New approvals can seriously delay product rollout, so be aware of the strength of the upcoming approval cycle. The more changes you make, the more attention you will probably draw to your product.
- New components may have restrictions in certain parts of the world. Know the issues you might run into for every region in which you’ll sell your part.
3. Redesign Considerations
Reputable electronics design companies should be able to redesign most boards, but make sure it’s possible to convert your specific product. Questions you should ask include:
- Can you redesign the board?
- Can you find SMT versions of components that match the form and function of the through-hole components?
- Are there any features you’d like to add from a sales/marketing standpoint since you're redesigning anyway?
4. In-House Engineering Requirements
Every company is different -- you may or may not have the capacity to handle quite a bit of the design yourself. Keep in mind the benefits of contracting with electronics design companies that have engineering capabilities.
You’ll avoid communication issues and avoid overengineering with the new product team. Plus, everything will stay at the scale and volume you’re looking for.
5. Compatibility
Does your product need to be backward-compatible with existing equipment in the field? Your electronics contract manufacturer can give you options concerning compatibility, but ultimately it’s up to your upper-level management.
Backward compatibility costs more, but the increased customer satisfaction may make it worthwhile.
6. Is This an Internal or External Job?
A contractor with capable electronics manufacturing design services can support your redesign. It can quote the scope of the work and ask you the right questions -- like those in this list -- to determine the optimal PCB design and how much it will cost.
7. Prototyping & Testing
Determine the number of PCB prototypes you’ll need and what types of PCB testing you’ll require. Understand your prototype run and how to design for manufacturability to avoid:
- Extra work
- Delayed production
- Increased costs
8. Obsolescence Management
The electronics contract manufacturer should understand life cycle management so it’s not designing with obsolete or end-of-life components. The contractor should use parts that have a good outlook in terms of life span.
You don’t want to spend all this time redesigning the part only to produce something that’s nearing obsolescence before it comes off the line.
Other PCB Assembly Questions
If you have questions about transitioning a PCB assembly from through-hole to surface mount technology -- or anything about electronics product PCB design in general -- let us know. We advise OEMs on the entire PCB production process from design to packaging, so nothing you ask will scare us!
Almost everyone uses devices that incorporate printed circuit boards every single day. It might not be known that these are being used, but they are so widespread and offer so many benefits that almost everyone has them in nearly all of their electronic devices. Used to create electronics, there are many applications for printed circuit boards, many of which use surface mount technology (SMT) to integrate components faster and more efficiently than past technologies.
The Basics of Printed Circuit Boards
A printed circuit board or PCB is a board used to connect electronic components. These are essential parts of all the electronics that people use at home and work each day. PCBs are made using non-conductive material and come with pads, lines, and other features that are etched from a sheet of copper that can electrically connect various components inside of a device. When SMT technology is included, things like resistors and capacitors are soldered onto the board rather than using wires.
Today, PCBs in electronics are common and the most popular way to create new products. The boards themselves can be single-sided, double-sided, or multilayer. They also come in flexible or rigid configurations or can combine both based on need.
PCB Assembly Options
There are two typical methods for assembly of PCBs and their components, including through-hole and surface mount.
- Through-Hole Mount – With this kind of mounting, an assembler will put components leads into holes that are drilled into a PCB. This is an older technology that is not used as often as it used to be. It has a strong connection since the leads run through the board, but it takes more time and effort to work with this kind of mounting technology.
- SMT Technology – With surface mounting, the components are connected to the PCB directly through soldering. The method was first created in the 1960s and gained popularity in the 80s. It’s the most common method of adding components today. Surface-mounted components are smaller so more parts can be placed on a board. This helps with the cost and has led to the proliferation of smaller devices year after year.
Common Uses for Printed Circuit Boards
It might seem like only a few sectors and industries would use printed circuit boards, but that’s not true. These little boards can be found in everything from massive pieces of machinery to small consumer devices. We want to share some of the most common applications for PCBs to give a basic idea of just how integral these items are for pretty much everyone.
LEDs
LEDs or light-emitting diodes are often used for lighting in both commercial and residential locations. LEDs are also used in many industries including computer technology, automobiles, and medicine. The biggest benefits of LEDs are their long life, energy efficiency, and compact size. PCBs are great for LEDs since they can help transfer heat away from the bulb. High temperatures make LEDs burn out faster, so the PCBs for them are typically made of aluminum to offer the best results. This eliminates the need for an extra heat sink and allows small, compact designs.
Industrial Equipment
The industrial sector uses printed circuit boards and SMT technology in many different ways. Electronic components are used for much of the powering of equipment in distribution and manufacturing centers, as well as other kinds of industrial environments. PCBs in industrial environments need to be exceptionally durable and high powered to handle harsh conditions since they may be around extreme temperatures, rough handling, harsh chemicals, or vibrating machinery. Many of them are made with thermal-resistant durable metals and are often thicker than typical PCBs.
Aerospace Components
Aerospace applications of PCBs require them to be capable of handling extremely harsh conditions. These printed circuit boards may be used in all sorts of equipment ranging from planes to satellites, space shuttles, and communication systems. The materials used for these PCBs need to withstand harsh conditions like extreme temperatures and large amounts of vibrations. Some are made to be used in outer space and are even more durable. Lightweight PCBs made of things like aluminum can also be useful in some situations.
Security and Safety Equipment
Whether used for homes, government buildings, or commercial businesses, security systems often rely on the use of PCBs and SMT technology. They have a huge effect on security and safety beyond what many are aware of. The PCBs used for these applications can vary based on the actual application, however, all should be reliable since these products must operate correctly at all times. Since some security devices operate outside the home or business, they need to be able to withstand that type of environment, as well. PCBs are used in everything from modern electronic door locks to security cameras, and even smoke detectors.
Medical Devices
New technology is constantly being incorporated into the healthcare sector and PCBs add additional capabilities to devices. Printed circuit boards are used in devices for diagnostics, treatment, monitoring, and more. These PCBs need to be exceptionally reliable since they are used to improve patient health. They also often need to meet specific sanitation standards and tend to work best when very small. Some of the devices that use PCBs in healthcare include medical imaging systems, infusion pumps, monitors, and even internal devices.
Electronics for Consumers
Computers, tablets, smartphones, and various other devices that people use every day need PCBs with SMT technology to function. As more electronics become part of everyone’s daily lives, PCBs are there to ensure they operate correctly. The boards allow smaller laptops and other devices while still creating the option of numerous capabilities. Most consumer electronics PCBs are relatively inexpensive to keep product prices low. However, the boards also need to be reliable to keep consumers satisfied.
Advanced Circuits offers a wide variety of printed circuit boards that can use SMT technology. We operate as a one-stop manufacturer and assembler of PCB solutions. We offer innovative technology with quick manufacturing and assembly for a wide variety of industries. Individuals and businesses can reach out to us with an order of any size to see what options we can offer.