Small Run SMD Line Recommendations - Page 1
Forum section: electronics / general

author: Evan.Cornell
author_rank: Regular Contributor
timestamp: April 05, 2022, 11:41:00 am
content: I am looking for recommendations for two scenarios for setting up a small SMD assembly / reflow line.Looking to do in the hundreds of boards per year, a few different designs likely, relatively high board complexity (i.e. unique component count up to 100 BOM items - sometimes placement down to 0201 and 0.65mm pitch BGA).Typically would do batches of 10 boards at a time for testing/iteration.There would likely be no 3 phase power at install location, possibly some size restrictions, standard doorway width. Location is New England, so used equipment from Boston-area may be an option, although I have no idea how to best approach sourcing this.Thinking that components required are:stencil printer (likely manual)automatic pick & placereflow oven (probably small conveyor?The two scenarios:~$50-60k USD - would like to be able to handle up to 100 unique components, not sure if this is realistic~$25k USD - what limitations would this price range incur?

author: Psi
author_rank: Super Contributor
timestamp: April 05, 2022, 12:11:36 pm
content: What's the reason do setup an entire PCBA assembly line yourself vs just paying somewhere in china to populate the boards for you?I ask because a few "hundreds of boards per year" doesn't seem like much of a reason to need your own PCBA line.Unless those boards are extremely profitable. Or there is some critical IP protection required , etc..

author: SMTech
author_rank: Frequent Contributor
timestamp: April 05, 2022, 12:15:58 pm
content: I'd probably start by reading the 6+ other fairly active threads on the same topic and budget but... My2p100+ unique BOM lines is instantly out of reach of the Chinese P&Ps that seem to focus on 48 or 64 peak feeder slots.Larger parts use more slots, exactly how many slots varies between manufacturer. "120" as is typical on a vanilla pick and place, might not be enough depending on your mix.0201 probably means you would be better with electronic feeders, or at least enough for what you need and the rest cheap pneumatic, many platforms let you mix if they have a pneumatic feeder history. 0201 again will push the limits of most Chinese platforms. 0.65mm BGA however shouldn't be all that scary.I'd say 0201 is zero fun to print by hand, manual alignment is a bitch, board support and fixing to get a good stencil gasket, also a bitch. 100% I'd say find an automatic printer hereI don't think what you describe justifies your own line, either you need to reduce your requirement & designs to make it easier to for with lower end setups or find a friendly CEM, we do exist.An Essemtec P&P from 2012 or later like a paraquda, fox or puma would be able to spec'd to have the feeder capacity you need, place the parts you want run on single phase and not take up crazy amounts of space. But you'd have to find one and with feeders the price might be more than you'd like; support would be good tho'. Compromising a bit you'd be looking at Samsungs, Yamahas etc that probably can't quite handle the crazy part count and have probably worked much harder but are more common and cheaper.A conveyor based oven is good but not many are single phase, you might find smallish 2nd user vapor phase batch reflow ovens tho, these have a fairly small footprint and might be IRO $10K something like thishttps://www.pmtech.co.uk/asscon-quicky-450-vp.htmlwhich would be about 25K new I think

author: Evan.Cornell
author_rank: Regular Contributor
timestamp: April 05, 2022, 12:19:13 pm
content: Quote from: Psi on April 05, 2022, 12:11:36 pmTurn time improvement, small quantity run price improvements, can't use China for some of the designs for business reasons.The reason for the price tier options is that there is capital funding available that won't be direct business expense, so it's more a one-time opportunity to set up a small line that could have price benefits later down the road.

author: Psi
author_rank: Super Contributor
timestamp: April 05, 2022, 12:24:14 pm
content: The 0201 requirement is what will cause you the most issues.You will need a pretty serious machine for reliability at 0201.Also don't underestimate the solder paste/stencil system.If the solder paste is not applied well it will cause problems.The solder pasting part of the process is far more critical than the conveyer oven reflow process.

author: Evan.Cornell
author_rank: Regular Contributor
timestamp: April 05, 2022, 12:29:02 pm
content: What if the requirement for 0201 is relaxed to 0402? Several designs, especially on the finer pitch BGAs are currently bypassed with 0201, but could potential work on re-design to 0402 if that significantly decreases SMD line requirements/expense.

author: georpo
author_rank: Contributor
timestamp: April 05, 2022, 03:41:40 pm
content: Considering the fact that you will be doing small batches of 10 a solution in order to keep the cost as low as possible would be to get a machine with let's say 100 feeder slots and just make 2 programs to assemble them. With quantities like that it's gonna be fine.An Assembleon Emerald would be quite fine I believe for what you need and can be found in good price as well.As about stencil printer for sure you will need an automatic one as SMTech mentioned. 0201 components on manual printer is absolutely bad idea.I've seen PCBs with 0201 & 0402 components from an Emerald machine and they were completely fine.

author: jmelson
author_rank: Super Contributor
timestamp: April 05, 2022, 04:12:22 pm
content: I do small batch size assembly in the basement of my home. I am now on my 2nd P&P machine. I made up my own stencil printing setup. I mostly use unframed stencils, but lately have started using framed ones from PCBway, they are so cheap it's crazy! I used to have a Philips CSM84, made by Yamaha, but have now upgraded to a Quad QSA30A, made by Samsung. These are both older machines, but are high-end production machines. 0201 are REALLY tiny, and will be difficult. I go down to 0603 passives, and also do TQFPs down to 0.5mm pitch. Those were what led to me having to upgrade, the Philips just wasn't accurate enough.As for reflow, I converted a GE toaster oven with a thermocouple "ramp and soak" controller and an SSR. You have to poke the thermocouple into a plated through hole in the board to sense the temperature of the board. Having the thermocouple in the air didn't work. The board is a good IR absorber, the thermocouple is not.The Philips/Assembeon GEM series machines all need 3-phase power, I think. My old CSM did not. 100 different type components/board is a REALLY big issue. Neither of my machines could come close to that! And, note that anything requiring over an 8mm wide tape uses up two feeder slots in the machine.Both of my machines were considered "compact" in the industry, and they were both about 5 x 7 FEET in size!I had to have a double-wide door installed.Jon

author: 48X24X48X
author_rank: Frequent Contributor
timestamp: April 06, 2022, 06:24:02 am
content: QuoteThese 2 alone will wipe off nearly all your machine candidates irregardless of your other requirements.Door width itself will leave you with those small but expensive Essemtec machines or smallest model from Chinese manufacturer up to 44/50 feeders.Both uses electrical feeder and can do 0201. My HWGC machine had to be dismantled it's top half and slide sideways to go through an 80 cm door. If you have like a 90 cm door, that opens up more machine possibility.Conveyor oven with single phase power is going to tough like @SMTech said. There's not many out there and noticeable ones are like IN6 from Neoden (there's some discussion in the forum), Puhui (not recommended) and a few more from China unverified (HWGC has one).And of course with 0201, you need a proper automatic solder paste printer. If volume is very low, of course you had to do them manually which I believe it is still doable but very dependent on the person that does it.