Production and installation of printed circuit boards in China. Small-sector electronics production in China, personal experience of non-professional. SMT installation of printed circuit boards to order in China

By doing electronics "for the soul" and not claiming the Lavra "Professional" and "Specialist" However, sometimes it is possible to create something interesting not only for yourself, but also for others. And here the question of making a small series is inevitably. About order printed circuit board Already many times wrote, many tried and, in principle, everything is less understandable here that and how. The first party is posted, stitched and given happy owners, all right. Suddenly it turns out that you need to make a couple of dozen boards, and the time to sit in the evenings with a tweezers and a hairdryer especially and no, and my eyes are sorry. The moment came to take the next step - try the PCBA service (PCB Assembly).

This article will deal with the already described adapter designed for simircing enthusiasts. The article is not a marketing research, I describe my personal experience.

To begin with, I remind you that you need to order the manufacture of naked printed circuit boards. If you already have a diluted board, you need to export GERBER and Drill files. For each printed circuit board layer, you need a separate gerber file. The number of the Gerber file must match the printed circuit board layer. I use DipTrace to wiring boards and when exporting Gerber files creates files with such names:

Boardoutline.gbr.
Bottom.gbr.
Bottommask.gbr.
BotTompaste.gbr.
Bottomsilk.gbr.
Through.drl.
Top.gbr.
TopMask.gbr.
TOPPaste.gbr.
Topsilk.gbr.

It would seem quite understandable? But with such file names, the archive will not accept seeedstudio. For all other files you have to rename:

Top Layer: PcBname.gtl
Inner Layer 1: PcBname.gl1 (for 4-Layer Board)
Inner Layer 2: PcBname.gl2 (for 4-Layer Board)
Bottom Layer: PcBname.gbl
Solder Stop Mask Top: PcBname.gts
Solder Stop Mask Bottom: PcBname.gbs
Top Paste: PcBname.gtp
Bottom Paste: PcBname.gbp
Silk Top: PcBname.gto
Silk Bottom: PcBname.gbo
NC Drill: PcBname.txt
Outline Layer: PcBname.gko or PcBname.do

Please note that when ordering printed circuit boards, the layers with soldering paste are usually not exported, but when ordering PCBA, they will be useful to us. Also do not forget to export the Drill file.

We will also need Bom (Bill of Materials) and a Pick-and-Place file that can be exported also from DipTrace (or that software you use). Moreover, the BOM can be made from the Pick-and-Place of the file, grouped the same positions and exclude those positions that you do not plan to plan. For example, I have provided a place to install a JTAG connector, but the connector itself soldered only on a fee used for debugging.

The format of BOM files is different in everyone, but the following fields should always be present in it:

1. Number
2. Manufacturer
3. Part-trailer manufacturer

For the Makerfabs service, where I eventually ordered an assembly, I did this BOM file:

References Qty Description Manufacturer MPN Digikey Mouser RS \u200b\u200bNEWARK Farnell
25/27 1 90131-0123 WM8121-ND 538901310123 6703443 60H4442 2381222
C1-C2 2 22PF, 0603 C0603C220J1GACTU 399-7874-2-ND 80C0603C220J1G 8015350 75R1532 1813429
C3-C4 2 100NF, 0603 C0603C104K5RACTU 399-5089-2-ND 80C0603C104K5R 8015347 72J5992 1692286
C5 1 4.7UF, 0603 CL10A475KL8NRNC 1276-6794-6-ND 81GRM188R60J475ME9D 6911155 62W5999 2211163
...

Requirements may differ, so it is better to check this moment in advance.

Also, do not forget about checking Design Rules / PCB Capabilities. As a rule, most services make it possible to download ready-made files for frequently used software, but for DipTrace, you need to check everything manually. On the other hand, with those rules that in DipTrace are "out of the box", most of the printed circuit boards are coping with a margin.

In case of fine dysfast (10-20 pieces) it is possible that it is manually to arrange components on the board. You need to make sure that the marking of all components on the board matches the BOM file, even if you have a Pick-and-Place file, where the location of each component is also indicated.

Suppose you coped with that, then you need to do the following. First, contact the service and ask them to send the cost of the cost of the project by sending them gerbera, the drill file, Bom and Pick-and-Place. Usually the answer comes within one or two days. Carefully look at the cost of positions. The account will include the following positions:

Production of printed circuit board
- Production of a stencil for applying a paste on the board
- selection of components from the number of local analogues (*)
- Installation and testing (**) (***)
- Delivery

(*) - reduces the cost of fees due to the replacement of the original components to the local, but also not for free, I cost $ 20. The fee for the selection is one-time, when re-ordering the same design is not charged.
(**) The test procedure can be discussed in advance, in small companies can perform any whim, of course, not free.
(***) If you order a small batch - a small commission for a small circulation can be added, for example, Makerfabs - with a lot of 20 pieces.

Making a stencil - also, in general, a single procedure, you do not need to pay when you re-order it, the Chinese promise to store them.

Note special attention On the delivery method. Small offices often do not have experience in working with the Russian Federation, can offer from the best motives to use some courier service whose name you will have little to say. At the same time, this courier service in the territory of the Russian Federation can work through, say, some EMS. And to suffer to you with him exclusively in your own fault ...

Again, do not forget to specify Taxpayer Number (INN) and ask the Chinese to specify it on the application form in order not to get problems from our customs. The Chinese may also ask, pointing on the box the cost fully or underestimated it. I asked to indicate completely, taxes from such an amount are not charged yet.

After the cost is agreed and the order is paid, the manufacturing stage is usually 1-2 weeks. Upon completion of the stage, you can ask you to send you a photo of the result, so that it was not boring to wait during the delivery :) So ask the report as the fees have passed a concerted testing with you. If everything is good - wait, soon arrives.

In general, the order processing cycle looks like this:

If you compare the cost of assembling yourself and assembling to order, then the question is resting primarily to what you evaluate your time. Personally, I assemble the fee as a CDPV somewhere in an hour. 10 boards - conditionally two working days. By comparing the cost of your working time and the cost of contract assembly is the second cheaper. Moreover, if we are not talking about 10 cards, but, say, about 50-100 pieces. Yes, there are specially trained installers who make it much faster and better. But it's not about me ...

When you definitely do not use the contract assembly? For example, if you are not fully confident that your design is fully operational. For this is exceptionally your problem, the collectors for this do not respond and the order will be assembled completely regardless of its performance. Well, at the end of January, too, it is not necessary to order. Made after January 20 Order You will see except in mid-March. Because all China celebrates the new year ...

Regarding the leakage of intellectual property - the service declares the intact of your intellectual property. How this integrity will be guaranteed - it is not very clear, but for the opening or hobby projects it is not so important. In the end, for the hobby of electronics, the scheme is usually quite simple, well, and the firmware can not be provided for testing. But you decide.

Installation electronic plats In enterprises in China - robots robots - happy man!

SMT installation of printed circuit boards to order in China

Electronics in China is improving and miniaturized very quickly

users hardly have time to get acquainted with the gadget and "rolling" it before it appears even more interesting in this regard. But competitions between manufacturers on the thinnest smartphone, tablet or other, reliable and convenient device are doomed to failure without using the finest, lungs and oversized printed circuit boards.

Therefore, the speed of "evolution" of PP increases today at times. In person, we can observe this process on the example of the subway, the global electronics center: installation of printed circuit boards in China is one of the most sought-after productions here. Large local businesses with the latest equipment, for a minute not stopping their work, and the possibility of implementing the most modern technologies Operatively and with absolute repeatability perform any orders for the assembly of printed circuit boards.

Technological features of the process

An intricate drawing of modern PP striking the accuracy of lines and clear, neat placement of their elements. The secret of such an elegant soldering of tightly installed chip components lies, first of all, in the use of progressive technologies for mounting printed circuit boards.

This is the most difficult and time-consuming stage of production, requiring and highly qualified personnel, and high-quality and productive equipment. Huge number of used electronic components, microspects, chips and varieties of their compounds on cards of various species, the number of platforms involved on the boards determine the choice of optimal technology soldering components.

Types of installation of printed circuit boards

Surface;
output;
manual.

The task of the masters of the manufacturer with each of these methods is to provide reliable and durable compounds and uninterrupted electrical contact. In addition, the selected technology should be economical and in terms of time, and in a financial aspect relative to each specific order. On the possibility to reduce the weight of the board and make it more compact, it is not worth mentioning - this is granted things.

SMT mounting

All high quality requirements are perfect surface installation of the printed circuit board. This is a fully automated economical process using high-speed installers, high-performance automatic printers, PP unloaders, accurately and quickly perform all operations. Such equipment can be quickly and easily reused on the release of boards of different types.

Advantages of surface editing of the printed circuit board

they allow us to talk about the efficiency and prospects of the method, especially in large-scale production. Along with a decrease in the dimensions and weight of the boards, the possibility of high-quality installation SMT components of small sizes and dense tracing, technology allows you to improve the reliability and accuracy of products by automation manufacturing process and careful control of its stages.

Such fees are more durable and distinguished by high sensitivity when transferring even the most weak signals. And, which is important - they are well repaired, thanks to a simple replacement of components. The deadlines for the release of large batches of orders and costs for such production are minimized. Naturally, the cost of PP is noticeably declining.

For soldering of components with flat conclusions directly to the surface of the PP, the technologies of melting in the furnace or soldering wave of solder are used.

Melting technology consists of several stages:

Potor or screening of soldering paste on contact pads or glue to points of placement of elements on the board surface. Depending on the amount of order, the operation can be performed in manual, automatic or semi-automatic mode. It is very important at this initial stage, when the basis of the board is laid, accomplish the accuracy and uniformity of application of paste to obtain a qualitative product as a result;

Installation SMD components. Unlike the output method, the installation during surface soldering is less time-consuming and more productive. In the manufacture of test samples or minor batches of boards, manual or semi-automatic manipulators with vacuum tweezers are used. In mass production in Chinese enterprises, expensive automatic installers With the possibility of contactless centering elements of fees, support different types feeders, high speed reference systems for different types of boards;

Playing paste in special furnaces of the Cabinet or Conveyor Types with various quantities Heating zones. Complex and responsible fees are melted in convection furnaces creating identical soldering conditions for all connections without exception. More simple boards can be processed in infrared and mixed furnaces;

Automatic X-ray, optical, intrahemny control to assess the quality of the soldering, the correctness of the assembly and testing of productivity of products is carried out at all stages of production;

Flashing boards in ultrasound baths, rinse deionized water, etc. To remove paste residues.

When soldering the wave in the inert board after pre-fluxing and heating, they are stacked on the conveyor belt and pass over the wave of the solder. And immediately the air knife eliminate the remains of the solder.

Manual installation of plants

With single orders of prototypes or trial batches of PP, Chinese manufacturers use a manual assembly. It is more expedient in terms of efficiency and technical features process. But in no way speaks of low product quality or low performance speed.

Technology, by and large, identical to automatic assembly, but using manual manipulators. Soldering is performed on modern specialized equipment with constant verification and control of all operations.

Output mounting

Until recently, it was the main type of PP mounting. And although more productive and efficient methods have appeared, the classical technology still finds the use. The name itself is already talking about the features of the method: the components are installed in the openings of the board and are attached to the soldering to their inner metallized surface or contact sites.

Depending on the number of elements installed, their size, the locations on the boards and complexity of the board circuit can be used. different kinds Output (pin DIP) Installation:

Soldering wave (used for one-sided installation. It has a high execution rate, excellent repeatability due to the process automation, good quality compounds and absence of oxides);

Selective soldering (economical automated method of electoral installation of elements on the boards of mixed type. Like a soldering wave, produced in nitrogen medium);

Manual soldering on soldering stations (applicable to mounting varying degrees of complexity, rational in the manufacture of prototypes or small batches of boards).

How to win in price and quality?

In the production of printed circuit boards, one of the most important factors holding the competitive position of the manufacturer's competitive positions, there are always opportunities to reduce the cost of products without prejudice to quality. The most efficient solution in this case is contract production, which allows to optimize the customer's financial resources and reduce the time of the manufacturing process. China's high-tech production enterprises in this regard are in the most advantageous position, and not only because of the cheap labor.

In China, it is not necessary to look for the necessary components for a long time - hundreds of thousands of various electronic components of PP are being developed and produced. And their cost and quality are by no means plot in the shock of a foreign customer. A professionally debugged production algorithm is one of the main features of Chinese enterprises that fulfill contract assembly of printed circuit boards, and it prefers more and more foreign companies.

EWBC during partnership with Chinese manufacturers helped foreign customers to fulfill dozens of projects for the manufacture and installation of boards of different degrees of complexity and accuracy, including high-tech PP, as well as installation of SMD components.

We offer individual work with each client for spent schemes of mutually beneficial cooperation, regardless of the volume or features of the order.

Cares for ourselves I usually made on my own LUT-technology. But in the last my projects collided with technological restrictions. The need for making at least a two-layer printed circuit board forced me to refer to the industrial service for the manufacture of printed circuit boards.

The study of this issue on the Internet led me to the conclusion that it is most profitable to order the manufacture of printed circuit boards in China.

Recently, I managed to try the following services:

At the time of placement of the order, the most interesting offer was from AllPCB (at the moment the price could change, so we choose the service where the price is lower), as they have free shipping to Russia, when sending Hong Kong Post.

Here you need to specify the characteristics of your future fee.

• Dimension: Dimensions of the board width, height.
• Quantity: number in pieces (minimum 5, but the price depends on the amount).
• Layer: Number of layers.
• PCB Kinds: The number of boards on one textolite (usually, if you have several small boards, it is most advantageous to place them on one textolite size of 100x100mm, separating them into a layer of silk-screen printing, and then cut independently. Unfortunately, from AllPCB.com I did not pass. They counted my project as a few PCB Kinds, which greatly increased the cost. Thus, for the case of AllPCB, I recommend to restrict one board on one piece of textolite).
• Thickness: Textolite thickness.
• MIN SPACING: minimum distance between components.
• Min Hole Size: Minimum hole diameter
• Solder Mask Color: Color protective mask. The default is green, but you can choose another for an additional fee (SEEDStudio is free, but the quality of the green mask turned out to be noticeably better).
• Silkscreen Color: marking color.
• Surface Finishing: Surface treatment.
• VIA Process: We will define whether the transition holes will be launched under the mask (no sense to specify, since for GERBER, the default, the transition holes are processed according to the files).
• Flying Test: Testing tracks on breaking and closure (test free).
• Copper Weight: Copper coating thickness.

Thus, for amateur boards, it is enough to set the size, the number of pieces, the number of layers. Everything else leave the default.

Total the most profitable option of order is a fee 10x10cm in an amount of 10 pieces, a double-sided, green mask. If we have one fee (one species, you can place a few, but one species), then it will be more profitable to place an order from AllPCB.com. If you need to place a few copies of the board on a piece of textolite, it is better to use the service www.elecrow.com, they have a free panelization.

You can read more detail with the project yourself and download the files of the project itself, you can in the article

I will describe your order to order printed circuit boards in China. I decided to produce a small batch of my devices (the penteque - an electronic coin for making decisions) in the amount of 200 pieces and got a choice where to order printed circuit boards? In Zelenograd, they requested a very conservation price and after small search, I came across the site where the price for printed fees I was very pleased.
Many photos!

Prepare Gerber files, began to issue an order:


No difficulty on design did not arise. All intuitive.
Choosing the necessary options, the price was 1,683 rubles with kopecks. Highly good price For a batch of 200 pieces!
Adding an order to the basket, and by clicking continuing the design you fall into the section of the delivery and payment.
Since I was not in a hurry, I chose the usual delivery (it and more budget)


I was waiting for the cost of delivery 1000 with a little.
Paying the order, began to wait. After 14 days (very quickly, he was surprised) from the moment of payment fees were on my hands!


In parallel, I ordered a complete set in Russia. It seems all components and not expensive, but the amount came out about 17,000 rubles (including 200 boards)
Big box came out)))

And now the moment of truth is the moment! The assembly began!
Since the device is one, and two versions of two were written 2 firmware for controllers.
Only 2 LEDs work in the first version: green and red (answers and no, respectively)
In the second version, a yellow LED is added (the answer option to the question is asked by the user itself)

This is what happened (a small batch) without installed battery compartments.

With installed battery compartments, but with other buttons

The device was very tactful and scattered like hot cakes.
Yes, I confess, I did for sale, but I give at a ridiculous price)))

Wow! The effect is achieved like this: the question is asked, for example, can I order a pizza? And the button is pressed


Everyone has sadness - sadness (((

Is there sushi?

Wife rejoices !!!

Devices are collected, my wife is pleased and I am satisfied!