Product quality is maximized by meticulous process management. Our production skills at Vergent are best summed up by this remark. Combining error-proofing of upstream processes with a paperless Manufacturing Execution System (MES) allows us to head off problems before they even start. As a result, you can rest assured that your order will arrive promptly and accurately every time. Come take a look at our setup in action during a tour of our premises.
Fast turn prototypes
Our organization is known for its rapid prototyping and moderate-volume production runs for our clients. Superior printed circuit boards (PCBs) may be designed and manufactured with lightning speed and precision thanks to our team of highly trained engineers. Our cutting-edge factory can crank out everything from one-off prototypes to thousands of units at a time.
Automated Surface Mount Technology (SMT)
Electronic components can be attached to a printed circuit board (PCB) using a technique called automated surface mount technology (SMT). SMT is a critical technology in today’s electronics manufacturing sector, as it is the principal manufacturing process for the majority of PCB assembly. SMT is a fast method that provides incredibly precise part placement, which in turn leads to PCB assemblies of the highest quality and efficiency.
BGA and Fine Pitch Component Placement
When assembling a PCB, it is essential to pay close attention to both ball grid array (BGA) positioning and appropriate pitch components. Placement of devices with an outstanding pitch requires the usage of BGAs, while devices with a pitch smaller than the width of the trace are identified using acceptable pitch component placement. These two methods are crucial to making a high-density PCB.
Thru-hole PCBA Assembly
Thru-hole A printed circuit board assembly (PCBA) is the process of soldering electrical components to the board using the holes in the board. This assembly method is normally reserved for larger, non-surface-mounted components like transformers and connections. Each part’s leads are soldered into place after being put into the corresponding holes in the PCB. After everything has been soldered onto the printed circuit board, it is inspected for flaws.
Wave and Selective Solder for Thru-hole Components
Both wave soldering and selective soldering are commonly used to join components with through-holes.
Soldering circuit boards with a wave soldering iron typically use a tin-lead alloy. Leaded components, like those seen in older electronic gadgets, are often soldered using this method. However, lead-free solder is commonly employed in selective soldering. Soldering in accordance with RoHS standards is utilized in modern electronics.
Multiple Solder Chemistry Options (No-Clean, Water Soluble, RoHS, Leaded)
There is a wide variety of solder chemistry that can be used for electronic construction. No-clean, water-soluble, RoHS-compliant, and lead are four of the most popular options. There are benefits and drawbacks to each type that must be weighed carefully before settling on one.
When using no-clean solders, you won’t need to clean the parts after assembly is finished. Time and effort savings may result from this, making it a potential advantage. No-clean solders, on the other hand, can be more difficult to deal with and less trustworthy.
Solders that can be cleaned with water must be rinsed after assembly. Getting rid of any traces of solder left over is an advantage of this method. Water-soluble solders, while convenient, aren’t always the easiest to deal with or the most dependable.
Products that adhere to the Restriction of Hazardous Substances Directive must use RoHS-compliant solders. Depending on the application, RoHS-certified solders may cost more than ordinary solders.
When putting together electronics, the go-to choice of solder has always been a lead-based variety. Lead-based solders have been phased out of numerous uses due to environmental and health concerns. There are still uses for lead-based solders, though, where RoHS compliance is not a necessity.
IPC-A-610 Class 2 and 3
When it comes to accepting electronic assemblies, the IPC-A-610 is the gold standard. IPC’s standard is the gold standard for PCB assembly around the world. The aerospace, automotive, military, and medical sectors are among those that make use of this standard.
Class 2, Class 3, and Original Equipment Manufacturer (OEM) are the three levels of IPC-A-610 compliance. Class 2 is the most common and is appropriate for many industrial uses. Class 3 is utilized in extremely reliable applications, such as those found in the military and healthcare. Original Equipment Manufacturers (OEM) is the term used for the most reliable manufacturers.
When it comes to printed circuit board assemblies, the IPC-A-610 standard is crucial for reliability. Inspectors rely on it to guarantee that finished products are up to par with user expectations.
Over the past few years, automated cleaning systems have become increasingly commonplace in the Printed Circuit Board Assembly (PCBA) sector of the electronics manufacturing business. The necessity for increased industrial efficiency and the aim to lessen the cleaning process’s negative effects on the environment are driving this development.
Automated cleaning systems come in a variety of forms, each with its own set of pros and cons. Ultrasonic and jet-spray techniques are particularly well-liked. In order to clean the PCB’s surface, ultrasonic devices use cavitation bubbles formed by high-frequency sound waves to dislodge impurities. To purge contaminants, jet-spray devices hurl streams of water or another liquid against them at high pressure.
Oils, greases, flux residues, and dust are all easily cleaned away by either ultrasonic or jet-spray cleaning systems. Typically, ultrasonic systems are better at removing smaller pollutants, whereas jet-spray systems are better at eliminating bigger impurities.
A Printed Circuit Board Assembly (PCBA) can have its electronics shielded from the elements by applying a conformal coating to its surface. Thin layers of acrylic are widely used as conformal coatings because they establish a barrier between the underlying circuitry and environmental hazards like moisture and dust. A PCBA’s dependability can be increased with the help of conformal coating because it offers some protection from mechanical stress.
Automated Optical Inspection
Using dedicated equipment, a PCBA automated optical inspection checks for flaws on printed circuit boards. This device has a powerful camera and analysis software to check the boards for flaws. In order to guarantee the quality of the final product, the inspection process is essential.
Broad Testing Portfolio (Parametric, Functional)
The need for higher quality, more intricate PCBs is directly proportional to the expansion of the electronics sector. Board manufacturers are responding to this need by providing an expanding menu of testing options for their clients. Parametric tests and functional tests are the two primary types of testing.
There are two main types of PCBs, digital and analog. In contrast to analog PCBA testing, which primarily focuses on ensuring the reliability of the analog circuitry, its digital counterpart is focused on ensuring the proper operation of the digital circuitry. PCBA boards, whether digital or analog, can undergo parametric and functional testing.
Common electrical properties of a PCB that undergo parametric testing include voltage, current, resistance, and capacitance. You can use this kind of testing to make sure your PCB is up to snuff and that it was designed correctly.
The purpose of functional testing is to ensure that the PCB can carry out its specified task. The functionality of the PCB’s circuitry is often tested with this method. The functionality of a printed circuit board (PCB) can be tested, as well as its conformance to the design’s specifications, with the help of functional testing.
PCB assembly components like microcontrollers and FPGAs can be programmed in a number of ways, including in-circuit programming, standalone programming, and the use of a programming jig. The most typical method is in-circuit programming, which does not need to take the device off the PCB to perform the programming. Production programming, in which the device is programmed before being put on the PCB, often makes use of stand-alone programming. As a result, the proportion of correctly programmed devices can be increased, as unprogrammed components can be culled before final assembly. Last but not least, programming jigs are used for both in-circuit and standalone programming, and normally include a socket for inserting the device, as well as the hardware and software required for programming.
Robust New Product Introduction Process
To move from prototypes to pilot programs and then to full-scale manufacturing, many aspects of a new electrical product must be tried, tested, and found to work as intended. The following advantages will accrue from following a well-defined New Product Introduction (NPI) procedure:
-A shortened time to market.
-A reduced cost of entry.
-A simplified production procedure.
Our NPI method has been used for numerous successful product introductions in the fields of industry, aerospace, military, and medicine.
High-Velocity Lean Manufacturing
As part of our everyday operations, Vergent Products employs the entirety of the LEAN toolkit. Since we have been doing this for a while, we know how to get the job done swiftly and accurately while maintaining the highest quality standards. We have made substantial investments in our Quality Management System and manufacturing process controls because we are a metrics and process-driven firm. Our modern, paperless factory and expert assembly staff allow us to complete even the most intricate product builds. We are confident in our ability to meet or surpass your expectations because of our commitment to providing you with the greatest quality and service possible. Get in touch with us right away if you’re interested in our final product assembly offerings.
Complex Electromechanical Assembly
For the benefit of our customers in the Industrial, Defense, Aerospace, and Medical sectors, Vergent develops a wide variety of products. When it comes to PCB and electromechanical assemblies, we excel at the most difficult and complex jobs. Assembly, testing and packing are all part of our paperless, metric-driven production processes. Get in touch with us immediately to find out how we can assist you with your next assembly project.
A Printed Circuit Board (PCB) is a device used to link electronic components that consist of conductive rails, pads, and other features carved from copper sheets and attached to a non-conductive substrate. The Assembly of components onto a printed circuit board is known as a printed circuit board assembly (PCBA).
When you integrate systems, you bring together parts that wouldn’t normally work together. When discussing printed circuit board assembly (PCBA), the term “system integration” refers to the process of bringing together all of the components that make up the entire system. Everything from the PCB to the electronic components to the power supply to the wiring and the case itself is included. System integration is crucial to making a product that can be used by its intended audience and has all the features they need.
In-Flow Programming and Test
In-flow programming and test are performed as the final step in PCBA to guarantee the board is completely functioning. To do this, first, the program must be loaded onto the board, and then its functionality must be tested. Discrepancies, if any, will be addressed now. The board will be ready for usage once all tests have been completed successfully.
Extended Test and Burn-in
We are able to put our PCBAs through a rigorous testing and burn-in procedure to guarantee their superior quality in the end product. Through this method, we can detect flaws and guarantee the product will function as intended in the actual world. This thorough evaluation is carried out under the most severe, prolonged, and demanding conditions that will ultimately be encountered by the product in its final application.
Configure to Order
In the configure-to-order method of supply chain management, items are tailored to individual orders. There are typically three phases to this procedure: order entry, configuration, and fulfillment. Orders from customers are processed in two phases. The second step involves tailoring the product to the buyer’s needs. The third and final phase involves shipping the finished product to the buyer.
These days, many electronic systems that are considered “smart” need to be configured uniquely for each customer and subsequent market niche. The motivation behind Vergent’s Configure to Order (CTO) service is to meet the demands of customers who want customized firmware and software pre-installed on mass-produced devices. We provide this final step of the production process to help our customers reduce their total lead time and a stockpile of finished items. Our CTO model is quick and effective since it completes all customization processes just before the product is packaged and shipped.
System configuration on demand is notoriously difficult and costly to achieve. However, they have the potential to provide substantial advantages.
In several steps of production, labels can be created and affixed to the finished good. Usually, the time of the labeling stage is coordinated with the timing of the product’s testing, and the label is printed on demand once the product has been given the all-clear for shipment after it has passed all necessary functional tests. Your company’s name and logo, as well as the product’s model number, serial number, QR code, etc., can all be printed by Vergent on the product label to your specifications.
Each item in a batch of manufactured goods can be guaranteed to be one-of-a-kind by employing automated serialization. This is done by assigning a unique serial number to each item when it is produced. Manufacturers may check that their products are up to par in terms of quality and consistency by keeping tabs on these identifiers, and they can also keep a record of the products’ assembly and testing, as well as store the results of those tests, in a database connected to the production system.
Due to the ever-increasing needs of consumers, automated serialization has become an integral part of many cutting-edge manufacturing procedures. Companies that prioritize quality over staying ahead of the curve should invest in this technology.
Electronic Device History Record (DHR)
The Device History Record (DHR) is a mandatory part of the medical device production process and a crucial part of the final assembly of any electronic product. Before releasing the product to the customer, it is the obligation of the final assembly operator to complete the DHR and get it signed off. All materials utilized, methods carried out, and inspection results are recorded in the DHR for an easy retracement. If you want to make sure your finished product is high-quality and trustworthy, you need this document.
We hope you enjoyed learning more about Vergent Products. Here at Vergent Products, we provide quality contract manufacturing services. From our state of art, we are able to provide quality contract manufacturing to a diverse and global client base. If you would like to learn more about how we can provide quality contract manufacturing to you, please visit our website at www.vergentproducts.com. Thank you for reading, we are always excited when one of our posts is able to provide useful information on a topic like this!