Industrial PCB Assembly; Offering Reliability and Precision!

Industrial PCB Assembly

When it comes to high quality industrial PCB assembly, Mer-Mar Electronics has emerged as a one-stop-shop. With over 4 decades of experience in fabricating and assembling a wide range of PCBs, Mermar Electronics is a trusted destination for a wide variety of clients. With access to the latest technology and equipped with a team of experts and industry best practices, we ensure that we develop cutting edge industrial printed circuit board assembly which are ahead of the curve.

Among our other offerings, we specialize in offering Industrial PCB assemblies that require a high level of reliability and precision. Since electronics used for industrial applications need to be extremely stable and fit to be used in harsh conditions, industrial printed circuit boards too need to follow stringent standards to thrive in industrial settings. Besides Industrial PCBs need to be resistant to temperature extremes, moisture & dust, shock, vibration and more.

Mer-Mar has over 40 years of expertise in bringing OEMs ideas to life. We are providing electronic assembly services to OEMs in the industrial and commercial industry. We understand the critical needs and challenges that OEM’s face. We have a team of experienced personals who are capable to fulfill tailor-made requirements of OEMs and offer end-to-end service to meet the challenges head on. We utilize state-of-the-art equipment, latest machinery and advanced systems to manufacture high quality products and assures customer of flexibility and on-time delivery.

We are capable to provide solution for varied industrial applications from sensing systems and monitors to heavy equipment and household appliances. We have the capabilities to offer low, medium and high-volume PCB assembly, box build assembly, cable and wire harness assembly, complete turnkey assembly and more solution for industrial applications.

Depending on the complexity of the circuit, we offer anything, from a single layer PCB to one with multiple layers. Also different industrial applications need rigid, flexible of rigid-flex PCBs. You can count on us to offer customized PCBs that do justice to your bespoke needs.

Our high-quality industrial PCB assemblies are known for the following features:

  1. Strong base material
  2. Thick solder resist layer
  3. Quality components
  4. Extensive testing

The Preferred Partner for
Industrial PCB Assembly

Rich Expertise – We have decades of experience in offering high quality industrial PCB assembly. You can bank on our team of experts to offer you the right selection of industrial PCB that suits your requirements. Besides having cutting edge technology, what we also have is access to industry best practices and therefore can recommend the right PCB to suit your needs.

Wide range of industrial PCB Assembly – Depending on your bespoke requirements, we offer a wide range of PCBs to choose from single, double layered to multi layered PCBs and more. We also offer rigid, flex and rigid flex PCBs that is most suitable for your industrial equipment. With Industrial PCB assembly needing a strong foundation, we offer a range of materials whose resilience and strength aids the PCB’s capability to support the intended application.

Suited for all volume requirements – We are well poised to support your volume requirements for industrial PCB assembly. Whether your need is for high or low volume industrial PCB assembly; you can bank on us to meet your needs.

Quick turnaround time – We take great pride in offering quality industrial PCB assembly with quick turnaround times. When you partner with us you can rest assured of sacrosanct timelines.

Industrial PCB Assembly Services

Layout and PCB Fabrication

We meticulously look into your full Gerber files and drawing packages for creating PCB layouts and for setting up equipment for PCB fabrication. Whether you have a new design or an existing one, we can quickly create and modify the layout effectively. You can discuss your project needs with our team of engineers who can schematically capture your design needs and go for PCB fabrication. We take every precaution to put the layers of the board with the specific surface patterns and assist you with a broader range of services.

Components Sourcing

In the competitive space, we thrive when it comes to component sourcing as we have built long-term relationships with authorized component suppliers. We are also diversifying more suppliers and purchasing channels for meeting varied customer needs. We also strictly comply with the quality control standards and full supply chain management to ensure you have the best quality components at an optimal price. Our rich experience and strong procurement capabilities are of no match in the industry as we meet even the unique demands.

Turnkey Assembly & Final Testing

Our turnkey assembly projects integrate in-house assembly, inspection, certifications, and other services. We are committed to helping our customers substantially reduce their production costs and improve efficiency by procuring components from authorized vendors. Our testing services for mass production include a wide variety to look into potential failures, reliability testing. We provide comprehensive turnkey services on finished products to meet the customers’ requirements and quality expectations. We speed up the entire process to shorten the time-to-market period.

Industrial PCB Manufacturing Process

The Industrial PCB manufacturing process involves the following steps:

PCB Design and Layout – This is one of the most crucial stage of the entire manufacturing process. A successful design supports the functioning of the device hence due attention needs to be paid to this stage. PCB design, of course, is influenced by the exact requirements of the industrial application and the environment it needs to work under. It is also influenced by the nature of users as well as access to resources.

Prototyping – Having a functional PCB prototype in place, to a large extent, mitigates the probability of any costly errors at a later stage. The prototype can ensure that both the function and features are tested. It is worth spending more time and investment on prototypes, as once this is in place, you can proceed to assembly.

Industrial PCB Assembly – This is the stage where the necessary components are etched on the board as per the design. The steps in this process include:

  1. Solder Paste Stenciling – This step involves application of solder paste to the board. The use of a stencil allows assemblers to apply solder paste only to certain parts of the PCB. With the use of an applicator solder paste is applied on the intended areas in precise amounts.

  2. Pick and Place – Next, the pick and place machine places surface mount components on the PCBs. The components are then soldered to the surface of the board.

  3. Reflow Soldering – This process involves moving the PCB board to a conveyor belt that moves through a large reflow oven. In turn, it melts the solder paste. The PCB next passes through coolers that allow the melted solder to solidify. This connects the surface mount components to the PCB. For two-sided PCB Assembly, the side with fewer and smaller parts is first stenciled, placed and reflowed, followed by the other side.

  4. Inspection and Quality Control Once the surface mount components are soldered the assembled board needs to be tested for functionality. Common inspection methods include:

    1. Manual Checks: These are particularly helpful for smaller batches where an in-person visual inspection can be carried out. This method, however, becomes impractical when the number of boards increase.

    2. Optical Inspection: This method works well for large batches. An AOI machine uses a series of high-powered cameras to inspect the PCBs. Different quality solder connections reflect light in different ways allowing the AOI to detect a low-quality solder.

    3. X-Ray Inspection: This method is used for complex or layered PCBs. It allows the viewer to see through layers to identify any potential problems.

  5. Through-Hole Component Insertion – The board could also contain other components besides surface mount ones. A plated through-hole in this case is plated all the way through the board. Instead of soldering paste, a manual through-hole insertion is used. Wave soldering can also be undertaken where once the plated through hole component is put in place, the conveyor belt runs through a specialized oven where a wave of molten solder washes over.

  6. Final Inspection and Functional Test – This step tests the PCB for its functionality. It simulates the circumstances in which the PCB will operate.

    The broad difference between industrial and commercial PCB manufacturing process is as under:

    1. Industrial PCB manufacturing requirements typically fall under class 2 or 3 while commercial PCBs fall under class 1 or 2.
    2. In terms of material quality typically high Tg material is used for industrial PCBs while standard FR4 is used for Commercial PCBs.
    3. Industrial PCB may require balancing between heavy and normal copper weights while commercial PCBs may not.
    4. Consistent temperature distribution is necessary for even flow of solder during PCBA for industrial PCBs.
    5. Industrial PCBs need moisture protection while commercial PCBs may not.
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Application of Industrial PCB Assembly

As their name suggests, Industrial PCB assembly find wide applications in a range of industries, including but not limited to:

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High volume PCB Assembly refers to bulk printed circuit board assembly projects of 10,000 pieces or more, in one cycle of production with DFM and DFT. This is highly popular in high-end modern electronic manufacturing companies.

The benefits of high volume PCB Assembly are

  • One-time design and prototyping services
  • Faster time-to-market
  • cost-efficient as you can purchase in bulk
  • Consistent quality
  • Production uniformity
  • Shortened production cycles

Choosing a high volume PCB manufacturing company is quite a daunting task in this cut-throat competitive space. Two of the most common things one looks for in any company are quality and cost-effectiveness. Besides, you can also look into their experience, manufacturing capabilities, turnaround time, responsiveness, value for time & money, flexibility, and customization options.

Mer-Mar Electronics is a USA-based PCB fabrication and manufacturing company with over 4 decades of experience in PCB assembly services. We are an ISO-certified and ITAR-compliant company. We offer high volume circuit boards in the least turn-around time, flexible shipment plans, and at competitive prices. We follow a client-centric approach to ensure guaranteed quality satisfaction.

You can send your Gerber files and BOM to us We would provide you the quote Give your confirmation and the order We start with PCB fabrication component procurement We perform soldering and testing Finally, we go for packaging and shipping to you.

Well, we can accurately present the time based on the complexity of your board. Let us first go through your Bill of Materials (BOM) and Gerber files. See how much time it takes.

Yes, we do. After the PCB assembly, we can launch an x-ray test on your components. The additional charges will be levied after the assembly test.

We make sure you face zero issues. However, if unfortunately, you face any problems with the boards, please send high-resolution images for proper evaluation. If we get a confirmation of the root cause, we will take responsibility for your board repairs.

As part of the high volume production process, we provide components and parts procurement for optimizing the manufacturing process at zero price. Also, repeat customers may also take advantage of loyalty discounts to reduce the long-term costs of production. Depending on your requirements, we would let you know the final costs.

Yes. We do offer reliable customer support for your orders from start to finish. We will walk you through every step of the process and our PCB experts will also be available all the time.