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8 Steps to Designing Electronic Products Using Surface Mount Technology
In most cases, SMT versions of through-hole PCB designs are available—the advantages of surface mount technology are numerous. However, failure to consider the typical challenges in transitioning to SMT can lead to costly obstacles.
If you're considering converting your existing electronics designs from through-hole technology to surface mount technology (SMT), you'll need to do your homework first.
In most cases, an SMT version of a through-hole PCB design is available—the advantages of surface mount technology are numerous. However, failure to consider the typical challenges in transitioning to SMT can lead to costly obstacles.
The following steps are intended to serve as a checklist for your transition. Once you've checked the boxes, you can proceed with confidence and make informed choices.
Making the Most of Surface Mount Technology: 8 Electronics Design Tips
1. Make Sure the Transition is a Good Idea
When comparing surface mount to through-hole, you'll find many advantages to surface mount technology, including:
Lower manufacturing costs. Once your SMT design is up and running, you can expect to spend less on product manufacturing costs. SMT is a good choice now for many reasons, and lower costs are one of them.
Smaller footprint. With few exceptions, all circuit boards in small mobile devices are SMT. Companies choose SMT because it has a smaller footprint, allowing them to deliver more product in a smaller package.
Faster manufacturing speeds. What might take hours on a through-hole board might take only five minutes on an SMT board.
However, you might want to stick with through-hole for reasons such as:
Durability. For applications where parts will experience significant shock, through-hole is more resilient.
Power. Many mobile devices still use through-hole for power ports because this connection can transfer power more effectively.
Keep in mind that even if you do transition to SMT for durability and power, some components may still need to remain through-hole.
2. Regulatory Approvals
Keep the following in mind when planning your PCB development to minimize regulatory approval issues:
Allow for component selection variances whenever possible. You may need to make changes to meet regulations.
Determine the regulatory impact of redesigns. New approvals can severely delay product launches, so be mindful of the intensity of upcoming approval cycles. The more changes you make, the more scrutiny your product may receive.
New parts may be restricted in certain parts of the world. Understand the potential issues you may encounter when selling parts in various regions.
3. Redesign Considerations
A reputable electronics design company should be able to redesign most boards, but make sure your specific product can be converted. Questions you should ask include:
Can you redesign the board?
Can you find SMT versions of components that match the form and function of the through-hole components?
Since you're redesigning, are there any features you'd like to add from a sales/marketing perspective?
4. Internal Engineering Requirements
Every company is different—you may or may not have the capability to handle a significant portion of the design work yourself. Keep in mind the benefits of contracting with an electronics design company that has engineering capabilities.
You'll avoid communication issues and avoid over-engineering with your new product team. Plus, everything will stay at the scale and quantity you want.
5. Compatibility
Does your product need backward compatibility with existing equipment in the field? Your electronics contract manufacturer can provide options for compatibility, but it ultimately depends on your upper management.
Backward compatibility is more expensive, but the increase in customer satisfaction may make it worthwhile.
6. Is This an In-House or Out-Sourced Job?
A contractor with strong electronics manufacturing design services can support your redesign. It can scope the work and ask the right questions (like the ones in this list) to determine the best PCB design and its cost.
7. Prototyping and Testing
Determine the number of PCB prototypes you need and what types of PCB testing need to be done. Understand your prototype runs and how to do design for manufacturability to avoid:
Overtime
Production delays
Increased costs
8. Obsolescence Management
Your electronics contract manufacturer should understand lifecycle management to avoid using obsolete or soon-to-be-obsolete components in the design. The contractor should use parts with a good lifespan outlook.
You don't want to spend all that time redesigning parts only to end up with a product that's nearing obsolescence before it even hits the production line.
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