There is a mark of growth in technology in almost all dominant industries across the globe. One of them is an up-gradation in mobile technologies with many new recent innovations like Code Division Multiple Access (CDMA) technology has extended promptly over the past few years which helps get a better quality, extensive coverage and better security access. As we proceed towards 2020 it is likely that there will be billions of people connected to devices worldwide. Everything from home appliances to our cars to the basic consumer goods will be connected to the network and 5G is being planned and launched with this concept. Privacy and security are also key factors emphasized in 5G network, which contains capabilities to ensure that data is secured and the devices have lesser possibilities to get hacked. A key essential for 5G is an increase in connection speed that is far superior to those experienced now.
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Aerospace being the technology driven industry has shown a revival in missiles, spacecrafts and aircraft machines. The aerospace industry has shown a stemming development in technologies which includes unmanned aircraft technology and novel technology that combats flight pollution in the air. A new kind of plating technique has been implemented which protects the commercial jet interiors to get rid of flames and fire. This new technique of coating is also used in fabric industries, wood-based industries and in the architectural industries. The aircraft equipments are in high demand in the defense sector with powerful innovations in jet engine aircraft through navigation technology and material science. Few of the major defense industries worldwide have collaborated to enter into the adjacent markets concentrating on research and development to create next generation technologies.
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New technological trends are enhanced in the robotics industry as there are various techniques introduced to develop the new version in the robotics. There is a great boom of demand and use of highly automated robots which are derived with the help of a technology programmable logic controller. Most of the researches related to robotics have core focus not only on the specific industrial tasks, but also in new varieties of robots, designs and new ways to fabricate them. One of the recent robotic technologies introduced in the market is an unmanned aircraft in which researchers have designed the world’s smallest open source autopilot for small automated aircraft. A compact and light weight autopilot allows these small flying robots to fly higher for a longer period of time with capacity to carry more weight.
The base element of any electronic designing and manufacturing solution is printed circuit board. To get an exact end to end solution for your electronic project, there are many different types of PCB Assembled with state of the art techniques as per the customer requirements. The surface mount technique, chip- on board technique and other techniques are used for prototyping and PCB Assembly process. The Power link technology is used for designing and fabricating of the printed circuit boards using heavy copper for maximum reliability. Power link has been used in the military applications such as in weapons control systems, Radar systems power distribution panels and monitoring systems. It's believed that worldwide requirements will extend the application of the power link electronics product in near future. Technology is the main advancement in the major industries in order to address present markets and to create demand in the industries that are yet to be discovered.
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A printed circuit board is a self contained model of electrical support to surface mounted and socketed components in the electrical devices. The significance and combination of design, fabrication and customer demand of Printed Circuit Board plays a vital role in developing an exact product as specified by the customer. A trend of complete turnkey has been adopted in the market right from control conceptualization, design, surface mount or through-hole technique, assembling, testing and delivery of order to the customer.
There are international standards followed to maintain an assurance over quality as well as durability in the printed circuit board. This solely depends on the type and level of design created for a prototype. The challenges faced at the time of fabrication like inadequate fiducials ( reference point ) , polarity , hole size, tabs, proper paneling , dry parts, vias in pads, large deltas, thermal relief , leadless devices, close proximity of devices, trace cuts, proper finishing and clear laminate stack solely depends on the blueprint and the design of the prototype.
PCB fabrication process
Every product or prototype has a different layout as per the space allocation. There are special software to design the circuit model on the board. Raw materials are then arranged as per the volume of the production, the type of product and purpose of the product. According to the circuit pattern and model the quantity and quality of inputs are decided. This is a significant criterion to be considered to make the project a cost effective and qualitative one.
One can move forward with the PCB fab process after proper planning , design and adequate availability of raw materials .There are different types of process used for different kinds of PCB’s like two –sided, one sided and multilayered . To get started with the fabrication process the glass fiber is rolled to a particular thickness as per the design. The substrate material is curved by passing it to an oven. After that the layering of the copper foil are placed as per the size of the board. With this the holes are drilled on the layers as per the design and layout.
The copper is plated with the help of an additive or subtractive process. The inner layer core, copper foil and prepreg are combined together with vacuum, heat or pressure to laminate them thoroughly. This is when the PCB is to be fabricated with multi layers. The copper plating creates metallic base onto the holes and surface of the board. The outer layer is then coated with the same type of foil used in inner coating of the layers in circuit board. Tin plating is done to maintain the traces , pads and walls while operating onto the outer layer .
The strip-etch-strip process is used to remove developed dry resist from the coatings where the tin plate is not affected. Solder mask technique is being applied to level the panel. The CNC machine is used to cut the boards in equal sizes as per the PCB design and layout. At last the boards are tested for its durability and raggedness.
The fabrication process depends on the volume of orders and demand of the PCB assembly or fabrication services to make it a cost effective and qualitative one. There is a growing demand of innovative and strategic business models in dominant industries of USA. The demand of PCB fabrication service in USA has shown a remarkable growth in terms of quality of offerings and innovation. The business in user industries generated new orders in PCB fab in California . Thus current market trend is a fusion of various technologies for an error-free, optimal used resources and quick turnaround for the customers.
A prototype is a sample, template or an initial testing release for any new idea to be worked into for providing the electronic solutions. The brainchild to printed circuit board concept into the market was in the early 1900’s. With regards to the backward integration sensed in major dominant businesses, there is a mark of growing demand and need of PCB prototypes in all the major industries. The differentiating factor from that of other PCB fabricators are the varied kinds of PCB manufacturing services, time critical delivery of prototype and high quality assurance.
Apart from working on new concepts for prototyping, a complete turnkey with providing end to end solutions and a personalized approach to each PCB project acts as one of the significant drivers to generating a good customer base across the globe. Technology is at the heart of almost all the industries worldwide. The PCB prototype demand is addressed in the dominant industries like aerospace, defense, telecommunication, medical, pharmaceutical and chemical.
PCB prototyping and fabrication process
By using the Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM), the OEM’s or PCB manufacturer can commence smoothly for the PCB fabrication process. The selection of the material meld or the fusion of different components to be made as per the requirement of the customers also reflects the success of the PCB design and layout made by the technical experts. The advanced tools used at the time of prototyping are mainly for automated design analysis, algorithms and custom technical specimens.
After the copper coating is applied to the circuit board, the layout of the circuit will be printed on it and the unwanted copper will be ejected from the circuit. This will connect the circuit tracks on the board. On the board the holes are then drilled with a laser or a hard driller machine to connect the circuit tracks and hollow rivets are ejected into those holes to create an electrical flow in the layers of the circuit board. Different tactics and processes used to get a custom PCB prototyping are surface mount technique, reverse engineering of the electronic components, direct metallization, through-hole-technique and chip-on board technique.
The solder mask technique is then used for coating on complete circuit board. After the PCB is fabricated, its quality is being inspected to know the toughness and reliability of the prototype. The testing with regards to knowing the temperature profiling, issues pertaining to highly complex assemblies and to keep a check on resistance and density level at different nodes of the circuit board, there are many inspection techniques like thermal profiling, flying probe testing and functional testing.
TechnoTronix , one of the kingpins in offering tailor-made PCB prototypes has a flexible approach to use technical expertise and machines with moderate technologies which proves the reliability to load the project at the right time and economy. We have adopted flexibility to provide prototyping services with full or partial turnkey assembly as well as providing of prototyping service with consigned PCB assembly.
We strive to tender to a varied customization with optimal cost effective inventory management, effective procurement process of the components used in the PCB production, PCB manufacturing with 2, 4 and 6 layered engineering, testing, and shipping PCB prototype’s for small run production. Thus our capabilities have outreached to expertise in PCB fabrication, prototyping, assembling, designing and testing with high circuitry velocity, multi layering PCB and many features in a compact space.
In the New millennium, there has been a quick pace of changes in the technological trends. With the up gradation marked in the systems, process and operations in almost all types of manufacturing foundation, there is a rise in demand of a rare king of PCB Assembly Services. Some customers shop for fetching a complete end to end electronic solution and some require a customized PCB Fabrication Service. There are two PCB manufacturing and assembling methodologies i.e., turnkey PCB Manufacturing solutions and consigned PCB manufacturing solutions.
Nowadays customers majorly look for a holistic approach wherein the components and the inputs needed for the fabrication process are arranged by the manufacturer themselves and are responsible to complete the order till the PCB’s are delivered to the customers safely.
For the customers who are in search for a customized electronic solution demand for the consigned PCB Assembly wherein the raw materials are being arranged by the customers but the fabrication and assembling is done by the PCB Manufacturer.
As most of the end users shop for a cost effective electronic solution with high quality assurance and quick turnaround the trend of consigned PCB Assembly is showing a negative graph gradually. Complete turnkey assembly is more preferable for both high and low volume production and prototyping services.
As per the research, the reason why the complete turnkey assembly is highly in demand is that the EMS , OEM’s and PCB fabricators have an effective established supply chain with strong vendor management system . Other reasons for the same are economies of scale at the time of bulk PCB Manufacturing, risk of poor quality is minimized and the PCB’s are manufactured with using latest technologies in the fabrications process. Many even opt to go for a complete turnkey PCB Assembly when they tend for new innovations or new product launches. Thus to deliver the PCB’s as per the customer requirements is the centre point of focus in both the types of PCB assembly process.
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