Through hole lead forming services - Page 1
Forum section: electronics / general

author: John Coloccia
author_rank: Super Contributor
timestamp: August 20, 2015, 12:11:04 pm
content: I'm shrinking some of my products down and it requires vertical resistor mounting (yes, I know I can do surface mount. This is not feasible right now for a number of good reasons). I want to get my resistors formed for vertical mounting with a lock-in feature so I can just stuff the board, flip it over and solder.Does anyone have any experience doing this in the US? I'm almost toying with the idea of just bringing in a lead forming machine to do it, but the ones that can do this particular form are quite expensive.Any help is most appreciated.

author: Richard Head
author_rank: Frequent Contributor
timestamp: August 20, 2015, 12:30:36 pm
content: I purchased a bending and cropping machine many years ago that can do that. Here's their website.http://www.olamef.com/site/It is pricey though.

author: John Coloccia
author_rank: Super Contributor
timestamp: August 20, 2015, 01:07:39 pm
content: Quote from: Richard Head on August 20, 2015, 12:30:36 pmI'm looking at one of those, actually. Where were you able to buy it? Do you remember how much it was?

author: Richard Head
author_rank: Frequent Contributor
timestamp: August 24, 2015, 08:05:57 am
content: JohnIt was over twenty years ago so I really don't remember, but it wasn't cheap!I do remember though that the vertically mounted resistors only had a single V bend at the top. I would prefer a smooth round bend at the top. I only ever used it to crop and bend horizontally mounted components. The "lock-in" feature you mention I presume refers to an additional bend on the leads to hold them in position once they are inserted into the PCB. This unit does not have that facility.Once you have the machine adjusted you can pump thousands of components through it in a very short time. They also used to have an optional electric motor attachment so you didn't have to wind the handle but I rekon it's a waste of money as you can pump so many through the machine manually anyway.The machine is well made and works well once set up.

author: alexanderbrevig
author_rank: Frequent Contributor
timestamp: August 24, 2015, 08:14:17 am
content: Sorry to derail your thread but I just had to point out the design onhttp://www.olamef.com/site/

author: tautech
author_rank: Super Contributor
timestamp: August 24, 2015, 09:11:12 am
content: Quote from: John Coloccia on August 20, 2015, 12:11:04 pmThey'd have to be good reasons NOT to use SMD and if you're scared of SMD just use 0805 ....easy.I've still got thousands of TH resistors, but I'll never go back.

author: John Coloccia
author_rank: Super Contributor
timestamp: August 24, 2015, 11:26:24 am
content: Quote from: tautech on August 24, 2015, 09:11:12 amWhy would I be "scared" of it? It's so much easier to be able to put components anywhere without having to worry about the component leads hitting all of the potentiometers mounted on the bottom. Through hole is the pain in the butt, not SMD.Maybe you're thinking in terms of assembly? I would have them assembled. As good as my soldering skills are, building smt boards by hand us a bad use of time, and home grown reflow oven contraptions are more of a science experiment than a production tool.It's a simple matter production logistics and cost. It's a lot more expensive, and for some of the components I use I'm practically locked into just one specific part. Try sourcing reasonably priced thin film resistors. There's not a lot out there, and if I'm ready to go and Digikey is out, I'm looking at a 12 week delay. Either that or pay $.20 each for them instead of $.002, and possibly have to change my PCB footprints. It also significantly cramps my ability to experiment with various boards to create new designs, or even just use them as R&D platforms. There's also a psychological benefit of through hole for some of my customers. They expect to see some craftsmanship when they pop open the box.I looked at it and thoroughly researched it, and the bottom line is that in my case through hole is simply better for business. But that doesn't mean that these tiny little boards need to be horrifically difficult to build. I just need the right lead prep.

author: John Coloccia
author_rank: Super Contributor
timestamp: August 24, 2015, 11:26:59 am
content: Quote from: alexanderbrevig on August 24, 2015, 08:14:17 amIt's a new site, I think. I remember looking at their stuff before and I don't remember it being nearly as goofy.Anyhow, I think I found a service to do it. I'm waiting to hear back on cost. I'm still looking at some machines but honestly, I just want someone else to do it. There are a lot of things I can technically do for myself that I prefer to simply have other people do because they have nothing to do with my core business and they end up simply being a distraction. Drilling, powder coat, silk screening, PCB manufacture, etc etc. Bending resistor leads is one of those things that generates no additional value if I do it myself.

author: John Coloccia
author_rank: Super Contributor
timestamp: September 04, 2015, 11:40:00 pm
content: update:All of my lead form attempts fell through. They are alternately way too expensive or can't seem to understand what I want even when I point them to the picture on their own website of exactly what I want...usually both. It's proven to be a very frustrating experience. I've looked into just buying a machine myself, but they all seem to be in the $3000+ range to do what I need it to do. That's just too expensive right now. I can usually fit everything laying flat. It's just this particular board that's packed with 5 potentiometers, a kind of unique active EQ with gyrators, 6 opamps, etc etc that just really eat up all the room I have.But I did come up with a solution. It's not perfectly polished yet, but I took it for a test drive tonight and it works pretty well. When I have a moment, I'll post some pictures of what I did...and it wasn't expensive. Less that $100, including prototypes. Turns out it works for capacitors too. Really, anything you can imagine if you design it right.Anyhow, I just don't really have time to get into it right this second, but I'll at least post a rendering to ponder.