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Surface-mount components on a USB flash drive's circuit board. The small rectangular chips with numbers are resistors, while the unmarked small rectangular chips are capacitors. The capacitors and resistors pictured are ( metric) package sizes, along with a very slightly larger ( metric) ferrite bead. A MOSFET, placed upon a British postage stamp for size comparison.Surface-mount technology (SMT), originally called planar mounting,[1] is a method in which the electrical components are mounted directly onto the surface of a printed circuit board (PCB).[2] An electrical component mounted in this manner is referred to as a surface-mount device (SMD). In industry, this approach has largely replaced the through-hole technology construction method of fitting components, in large part because SMT allows for increased manufacturing automation which reduces cost and improves quality.[3] It also allows for more components to fit on a given area of substrate. Both technologies can be used on the same board, with the through-hole technology often used for components not suitable for surface mounting such as large transformers and heat-sinked power semiconductors.
An SMT component is usually smaller than its through-hole counterpart because it has either smaller leads or no leads at all. It may have short pins or leads of various styles, flat contacts, a matrix of solder balls (BGAs), or terminations on the body of the component.
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Surface-mount technology was developed in the s. By , surface-mounted components accounted for 10% of the market at most but were rapidly gaining popularity.[4] By the late s, the great majority of high-tech electronic printed circuit assemblies were dominated by surface mount devices. Much of the pioneering work in this technology was done by IBM. The design approach first demonstrated by IBM in in a small-scale computer was later applied in the Launch Vehicle Digital Computer used in the Instrument Unit that guided all Saturn IB and Saturn V vehicles.[5] Components were mechanically redesigned to have small metal tabs or end caps that could be directly soldered to the surface of the PCB. Components became much smaller, and component placement on both sides of a board became far more common with surface mounting than through-hole mounting, allowing much higher circuit densities and smaller circuit boards and, in turn, machines or subassemblies containing the boards.
Often, the surface tension of the solder is enough to hold the parts to the board; in rare cases, parts on the bottom or "second" side of the board may be secured with adhesive to keep components from dropping off inside reflow ovens.[6] Adhesive is sometimes used to hold SMT components on the bottom side of a board if a wave soldering process is used to solder both SMT and through-hole components simultaneously. Alternatively, SMT and through-hole components can be soldered on the same side of a board without adhesive if the SMT parts are first reflow-soldered, then a selective solder mask is used to prevent the solder holding those parts in place from reflowing and the parts floating away during wave soldering. Surface mounting lends itself well to a high degree of automation, reducing labor cost and greatly increasing production rates.
Conversely, SMT does not lend itself well to manual or low-automation fabrication, which is more economical and faster for one-off prototyping and small-scale production; this is one reason why many through-hole components are still manufactured. Some SMDs can be soldered with a temperature-controlled manual soldering iron, but those that are very small or have too fine a lead pitch are often almost impossible to manually solder without expensive equipment.
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Different terms describe the components, technique, and machines used in manufacturing. These terms are listed in the following table:[3]
SMp term Expanded form SMD Surface-mount devices (active, passive and electromechanical components) SMT Surface-mount technology (assembling and mounting technology) SMA Surface-mount assembly (module assembled with SMT) SMC Surface-mount components (components for SMT) SMP Surface-mount packages (SMD case forms) SME Surface-mount equipment (SMT assembling machines)[
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PCB assembly line: pick-and-place machine followed by an SMT soldering ovenWhere components are to be placed, the printed circuit board normally has flat, usually tin-lead, silver, or gold plated copper pads without holes, called solder pads. Solder paste, a sticky mixture of flux and tiny solder particles, is first applied to all the solder pads with a stainless steel or nickel stencil using a screen printing process. It can also be applied by a jet-printing mechanism, similar to an inkjet printer. After pasting, the boards proceed to the pick-and-place machines, where they are placed on a conveyor belt. The components to be placed on the boards are usually delivered to the production line in either paper/plastic tapes wound on reels or plastic tubes. Some large integrated circuits are delivered in static-free trays. Numerical control pick-and-place machines remove the parts from the tapes, tubes or trays and place them on the PCB.[7]
The boards are then conveyed into the reflow soldering oven. They first enter a pre-heat zone, where the temperature of the board and all the components is gradually, uniformly raised to prevent thermal shock. The boards then enter a zone where the temperature is high enough to melt the solder particles in the solder paste, bonding the component leads to the pads on the circuit board. The surface tension of the molten solder helps keep the components in place. If the solder pad geometries are correctly designed, surface tension automatically aligns the components on their pads.
There are a number of techniques for reflowing solder. One is to use infrared lamps; this is called infrared reflow. Another is to use a hot gas convection. Another technology that is becoming popular again is special fluorocarbon liquids with high boiling points which use a method called vapor phase reflow. Due to environmental concerns, this method was falling out of favor until lead-free legislation was introduced which requires tighter controls on soldering. At the end of , convection soldering was the most popular reflow technology using either standard air or nitrogen gas. Each method has its advantages and disadvantages. With infrared reflow, the board designer must lay the board out so that short components do not fall into the shadows of tall components. Component location is less restricted if the designer knows that vapor phase reflow or convection soldering will be used in production. Following reflow soldering, certain irregular or heat-sensitive components may be installed and soldered by hand, or in large-scale automation, by focused infrared beam (FIB) or localized convection equipment.
If the circuit board is double-sided then this printing, placement, reflow process may be repeated using either solder paste or glue to hold the components in place. If a wave soldering process is used, then the parts must be glued to the board before processing to prevent them from floating off when the solder paste holding them in place is melted.
After soldering, the boards may be washed to remove flux residues and any stray solder balls that could short out closely spaced component leads. Rosin flux is removed with fluorocarbon solvents, high flash point hydrocarbon solvents, or low flash solvents e.g. limonene (derived from orange peels) which require extra rinsing or drying cycles. Water-soluble fluxes are removed with deionized water and detergent, followed by an air blast to quickly remove residual water. However, most electronic assemblies are made using a "No-Clean" process where the flux residues are designed to be left on the circuit board, since they are considered harmless. This saves the cost of cleaning, speeds up the manufacturing process, and reduces waste. However, it is generally suggested to wash the assembly, even when a "No-Clean" process is used, when the application uses very high frequency clock signals (in excess of 1 GHz). Another reason to remove no-clean residues is to improve adhesion of conformal coatings and underfill materials.[8] Regardless of whether cleaning or not those PCBs, the current industry trend suggests carefully reviewing a PCB assembly process where "No-Clean" is applied, since flux residues trapped under components and RF shields may affect surface insulation resistance (SIR), especially on high component density boards.[9]
Certain manufacturing standards, such as those written by the IPC Association Connecting Electronics Industries require cleaning regardless of the solder flux type used to ensure a thoroughly clean board. Proper cleaning removes all traces of solder flux, as well as dirt and other contaminants that may be invisible to the naked eye. No-Clean or other soldering processes may leave "white residues" that, according to IPC, are acceptable "provided that these residues have been qualified and documented as benign".[10] However, while shops conforming to IPC standards are expected to adhere to the Association's rules on board condition, not all manufacturing facilities apply IPC standards, nor are they required to do so. Additionally, in some applications, such as low-end electronics, such stringent manufacturing methods are excessive both in expense and time required.
Finally, the boards are visually inspected for missing or misaligned components and solder bridging.[11][12] If needed, they are sent to a rework station where a human operator repairs any errors. They are then usually sent to the testing stations (in-circuit testing and/or functional testing) to verify that they operate correctly.
Automated optical inspection (AOI) systems are commonly used in PCB manufacturing. This technology has proven highly efficient for process improvements and quality achievements.[13]
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SMD resistors in original packaging - this packaging allows for use in a mounting machineThe main advantages of SMT over the older through-hole technique are:[14][15]
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Handling of small SMT components can be difficult, requiring tweezers, unlike nearly all through-hole components. Whereas through-hole components will stay in place (under gravitational force) once inserted and can be mechanically secured prior to soldering by bending out two leads on the solder side of the board, SMDs are easily moved out of place by a touch of a soldering iron. Without developed skill, when manually soldering or desoldering a component, it is easy to accidentally reflow the solder of an adjacent SMT component and unintentionally displace it, something that is almost impossible to do with through-hole components.[
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Removal of surface-mount device using soldering tweezersDefective surface-mount components can be repaired by using soldering irons (for some connections) or a non-contact rework system. In most cases, a rework system is the better choice because SMD work with a soldering iron requires considerable skill and is not always feasible.
Reworking usually corrects some type of error, either human- or machine-generated, and includes the following steps:
Sometimes hundreds or thousands of the same part need to be repaired. If due to assembly, such errors are often caught during the process. However, a whole new level of rework arises when component failure is discovered too late, and perhaps unnoticed until the end user of the device being manufactured experiences it. Rework can also be used if products of sufficient value to justify it require revision or re-engineering, perhaps to change a single firmware-based component. Reworking in large volumes requires an operation designed for that purpose.
There are essentially two non-contact soldering/desoldering methods: infrared soldering and soldering with hot gas.[21]
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With infrared soldering, the energy for heating up the solder joint is transmitted by long-, medium- or short-wave infrared electromagnetic radiation.
Advantages:
Disadvantages:
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During hot gas soldering, the energy for heating up the solder joint is transmitted by a hot gas. This can be air or inert gas (nitrogen).
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Disadvantages:
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Hybrid rework systems combine medium-wave infrared radiation with hot air
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Example of component sizes, metric and imperial codes for two-terminal packages and comparison includedSurface-mount components are usually smaller than their counterparts with leads, and are designed to be handled by machines rather than by humans. The electronics industry has standardized package shapes and sizes (the leading standardisation body is JEDEC).
The smallest case sizes available as of after are , , , and .[22]
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SMT (Surface Mount Technology) assembly has become a leading electronics manufacturing technology as far as performance and efficiency are concerned by electronics products. With high reliability guaranteed, low cost can be definitely regarded as the secondary key element that has to be considered by OEMs (Original Equipment Manufacturers).
SMT assembly procedure consists of so many steps each of which contributes to the quality of final products. Furthermore, any modification occurring to each manufacturing step may possibly cause a huge cost fluctuation. Therefore, its substantially positive to have a full understanding of SMT assembly procedure, which is also a shortcut to cost reduction without performance being sacrificed.
Generally speaking, SMT assembly procedure mainly contains the following steps: solder paste printing, solder paste inspection (SPI), chip mounting, visual inspection, reflow soldering, AOI, visual inspection, ICT (In-Circuit Test), function test, depanelization etc. And, a full understanding of the whole procedure helps you to reduce production cost.
SMT assembly starts from solder paste printing that aims to place a proper amount of solder paste onto pad on which components will be soldered. The quality of solder paste printing is mainly determined by three elements: solder paste condition, scraping angle and scraping speed.
High quality can never be obtained by SMT assembled PCBs unless solder paste is properly stored and applied. Solder paste has to be stored in a fridge to be kept in a low temperature and its temperature should be recovered to room temperature prior to its application on SMT manufacturing line. Moreover, the uncovered solder paste has to be used up in two hours. Apart from solder paste status, solder paste printer parameters should be properly set, which is especially true for scraping angle and speed since both parties are closely related with the specific amount left on pad.
Solder paste inspection in itself is an optional way to reduce cost because its better to reduce solder defects right now than to catch them later. SPI is not a must-be step in SMT assembly procedure but with it applied its beneficial to decrease your manufacturing cost and to improve the quality of products. After all, most defects in SMT assembly derive from solder paste printing and if they can be found out and dealt in the early phase, the threats possibly leading to defects in later stages of manufacturing will be decreased or even eliminated. SPI machine features two types: 2D and 3D. PCBCart owns a 3D SPI machine in the workhouse to provide better inspection service to customers.
Chip mounting plays a core role in SMT assembly process. Chip mounting is completed by chip mounters that differ from each other primarily in terms of speed and mounting capability. Some small components are normally placed by high-speed chip mounters that are capable of placing them quickly to make those components quickly adhered to the solder paste on pad.
However, big components such as BGAs, ICs, connectors, etc. are usually placed by multi-function chip mounters that run at a relatively low speed. As far as those components are concerned, alignment does matter. It takes more time to achieve alignment prior to chip mounting, which is why the speed of multi-function chip mounter is much lower than that of high-speed chip mounter. Moreover, some of the components used in multi-function chip mounter dont rely on tape on reel while some on tray or tube due to the limitations of size.
After chip mounting, its necessary to carry out visual inspection so that reflow soldering can be largely ensured to be without defects. The leading issues to be found out in this step include misplacement, missing parts, etc. The defects are extremely difficult to be dealt with once reflow soldering is done because they will be solidly fixed onto PCB. As a result, products reliability will go down and production cost will rise as well.
On the other hand, some components can be placed directly by hand in this step, including some large components, DIP components or those that cant be placed through chip mounter due to some reasons.
In the process of reflow soldering, solder paste is melted to generate IMC (Intermetallic Compound) to connect component pins and board. The temperature profile followed in the process of reflow soldering process covers preheating, temperature rise, reflow and cooling. Take lead-free solder paste SAC305 as an example, its melting point is approximately 217 so the solder paste cant be remelted unless the temperature of reflow soldering oven is higher than 217. Furthermore, the highest temperature of reflow soldering oven shouldnt be higher than 250, or a lot of components cant be melted due to their incapability to withstand such a high temperature.
As a matter of fact, temperature profile setting determines reflow soldering quality and helps reducing production cost. Thus, its better to find out experienced SMT assembler as a CM (Contract Manufacturer) who is fully aware of elements influencing SMT soldering quality and improvement measures. All the elements will lead production cost to be cut.
Up to now, components have been fixed onto PCB after reflow soldering, which means that the essential part of task concerning SMT assembly has been completed. However, the assembled boards can never be directly used in final products unless sufficient test and inspection have been made. Performance of solder joints can be inspected through the application of AOI that is capable of exposing some defects like tombstone, edge on, missing components, misplacement, orientation, bridging, empty solder etc.
X-ray inspection is a supplement to AOI since it is capable of indicating some defects more clearly and directly. Its not a must-be measure after reflow soldering. However, as long as the SMT assembler cares more about products quality and reliability, X-ray inspection machine will be definitely applied to meet the rigorous demands of some OEMs for the achievemtn of higher efficiency.
The aim of ICT is to test whether opens and shorts are available in the circuit and to expose some defects of some components by measuring resistance, capacitance and inductance. As a result, components are tested to ensure their high performance after reflow soldering.
Function test is a supplement of ICT since ICT can only test the opens and shorts on bare board but the functions of assembled PCBs fail to be tested. Therefore, the functions of assembled PCBs should be tested through function test in order to maintain the high reliability of final products.
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