PCB Assembly

The files required for PCB assembly depend on whether you’re starting from scratch or providing a pre-fabricated PCB. Below are the requirements for each scenario:

Scenario 1: Starting from Scratch (Including PCB Manufacturing)

If you need both PCB manufacturing and assembly, the following files are required:

• Gerber Files: Detailed PCB layout files, including copper layers, solder mask, silkscreen(optional), and drill data, required for manufacturing the PCB.
• Bill of Materials (BOM): A professional BOM must include the following:
  • Company Part Number: A unique identifier used internally by your company for tracking components.
  • Component Part Numbers: Manufacturer’s or distributor’s part numbers to ensure accurate sourcing.
  • Quantities: The number of each component required for a single board.
  • Value: The electrical specification of the component (e.g., resistor values, capacitor ratings).
  • Designators: Labels like R1, C2, or U3 that map components to their positions on the PCB.
  • Alternate Part Numbers: Backup components for sourcing flexibility in case of shortages.
  • Footprint: The package name of the component (e.g., 0603, SOT-23, QFN), which ensures compatibility with the PCB layout and assembly process.

For multi-SKU products, create a Master BOM that lists all components for every SKU. Include a separate column or sheet indicating which components are used for each SKU. This approach avoids confusion and ensures that the correct components are assembled for each variation.In different companies, there are other varying approaches.

• Pick-and-Place File (Centroid File): Provides X-Y coordinates, rotation, and board side (top or bottom) for all components.
• Stencil Data (Gerber for Solder Paste Layer): Specifies the stencil design for solder paste application during SMT assembly.
• Assembly Drawings: Visual guides showing component placement and orientation. For multi-SKU products, include separate assembly drawings for each SKU, clearly highlighting variations in component placement or assembly instructions.
• Testing Requirements: Provide the following testing files for functional or in-circuit testing:
  • Test Specification Document: A detailed description of the tests to be performed, including the methodology.
  • Test Point Layouts: Gerber files indicating the locations and labels of test points.
  • Expected Results: Parameters (e.g., voltage levels, current values) for validating the board’s functionality.

Scenario 2: Providing a Fabricated PCB (Surface Mounting Only)

If you already have a fabricated PCB and only need components mounted, the following files are required:

• Bill of Materials (BOM): Include the same elements as above but tailor it for multi-SKU scenarios. A Master BOM should cover all components across SKUs, with a clear indication of which components apply to each SKU. This can be achieved by:
  • Adding a column to denote SKU applicability for each component (e.g., “SKU A,” “SKU B”).
  • Creating a separate BOM for each SKU if variations are extensive, ensuring clarity and avoiding errors.
• Pick-and-Place File (Centroid File): Includes X-Y coordinates, rotation, and board side (top or bottom) for each component.
• Stencil Data (Gerber for Solder Paste Layer): Ensures precise solder paste application for SMT assembly.
• Assembly Drawings: Include tailored drawings for each SKU, clearly indicating component variations. Ensure that assembly differences are visually distinct to minimize errors during the process.
• Testing Requirements: Provide the following testing files for functional or in-circuit testing:
  • Test Specification Document: A detailed description of the tests to be performed, including the methodology.
  • Test Point Layouts: Gerber files indicating the locations and labels of test points.
  • Expected Results: Parameters (e.g., voltage levels, current values) for validating the board’s functionality.

At Magellan Circuits, we employ proactive strategies to address component shortages and sourcing delays, ensuring your projects stay on track.

We maintain a robust supplier network by collaborating with trusted global suppliers. This enables us to source components from multiple channels and secure alternatives quickly if specific parts are unavailable.

For long lead-time components, such as certain FPGAs with procurement cycles extending up to 52 weeks, we recommend and facilitate advanced purchasing. By procuring critical components ahead of production schedules, we ensure their availability when needed, minimizing potential delays.

Our inventory management system helps us monitor stock levels and anticipate demand. This allows us to act proactively in securing parts before shortages occur. For critical or high-demand components, we also maintain buffer stock to ensure continuity during supply chain disruptions.

To reduce risks, we encourage customers to include alternate part numbers in their Bill of Materials (BOM). These pre-approved substitutes provide flexibility, allowing assembly to continue even if primary components are unavailable.

In urgent cases, we rely on expedited shipping to fast-track delivery of critical components. Air freight and priority courier services significantly shorten transit times, ensuring your project stays on schedule.

For hard-to-find components, we leverage premium procurement services, which provide access to exclusive inventories and specialized sourcing networks. This ensures that critical parts are secured even in constrained markets, though premium pricing may apply.

By sourcing exclusively from authorized distributors, we ensure the authenticity and traceability of all components, reducing the risks of counterfeit parts and unexpected delays caused by quality issues.

Finally, we maintain close collaboration with customers throughout the process. By identifying high-risk components early and tailoring procurement strategies to specific needs, we minimize disruptions and keep your projects on track.

Magellan Circuits offers a comprehensive suite of in-house testing capabilities, ensuring your PCB assemblies meet stringent quality and reliability standards. Our state-of-the-art infrastructure and tailored processes deliver accurate results for every project.

In-Circuit Testing (ICT)

Our ICT systems are equipped to handle over 2,500 test points, making them ideal for large and complex PCBs.

• Detects shorts, opens, incorrect component values, and solder joint defects.
• Custom-built test fixtures ensure precise and reliable testing for any PCB design.
• Efficient for both high-volume production and prototypes, catching assembly defects early to minimize rework.

Functional Circuit Testing (FCT)

FCT validates the performance of fully assembled PCBs by simulating real-world operating conditions.

• Custom hardware and software setups ensure the PCB functions as intended in its final application.
• Identifies hidden defects such as communication faults between components and system-level malfunctions.
• Flexible for various designs, from simple boards to intricate multilayer assemblies.

Automated Optical Inspection (AOI)

Our high-speed AOI systems deliver fast and precise inspection of surface-level defects.

• Detects soldering issues, component misalignments, and polarity mismatches with high accuracy.
• Suitable for PCBs of all sizes and layouts, making it ideal for both low- and high-volume production.

X-Ray Inspection

Advanced X-ray systems allow us to inspect concealed solder joints and internal structures.

• Ideal for Ball Grid Arrays (BGAs) and other hidden components.
• Identifies voids, cracks, misalignments, and solder defects not visible through optical inspection.
• A non-destructive testing method that ensures quality without damaging the assembly.

Flying Probe Testing

For prototypes or low-to-medium production volumes, flying probe testing offers flexibility without requiring custom fixtures.

• Tests continuity, resistance, and capacitance with high precision.
• Cost-effective for smaller runs or designs still in development.

Environmental and Stress Testing

We subject PCB assemblies to rigorous environmental and stress testing to ensure reliability and durability in real-world conditions. These tests include:

• Aging Tests: Simulate extended operational use to detect early-life failures.
• Drop Tests: Assess mechanical integrity and resilience under impact forces.
• Vibration Testing: Ensure reliability in dynamic environments such as automotive or aerospace applications.
• Wear Tests: Validate the durability of components under repeated friction or mechanical stress.
• Key Lifespan Tests: Specifically assess the durability and responsiveness of mechanical buttons or keys, ensuring consistent functionality over thousands of cycles.
• Thermal Cycling: Evaluate solder joint and material performance under rapid temperature changes.
• Humidity Testing: Assess reliability in high-moisture environments, ensuring long-term stability.

By combining these environmental and stress tests, Magellan Circuits ensures your assemblies meet the demands of challenging operational conditions.

At Magellan Circuits, we understand that protecting your intellectual property (IP) is critical when working with custom PCB designs. We take comprehensive measures to safeguard your designs and ensure confidentiality at every stage of the manufacturing and assembly process.

Strict Non-Disclosure Agreements (NDAs)

Upon request, we sign legally binding NDAs to guarantee that your proprietary information will not be shared with third parties or used outside the scope of your project. This provides an additional layer of assurance for sensitive or high-stakes projects.

Controlled Access to Design Files

Access to your design files is restricted to authorized personnel only. Our internal systems are secured with role-based permissions, ensuring that only team members directly involved in your project can view or modify your data.

On-Site Manufacturing and Assembly

All manufacturing and assembly processes are conducted in-house at our secure facilities, reducing the risk of exposure to external parties. By minimizing the use of subcontractors, we maintain full control over your project’s confidentiality.

Employee Confidentiality Training

Our staff is regularly trained on the importance of IP protection and confidentiality. Strict policies and procedures are in place to prevent accidental breaches, reinforcing our commitment to safeguarding your designs.

Customizable IP Protection Measures

We understand that every customer’s needs are unique. For projects requiring additional security, we can implement customized IP protection measures, such as segregated workspaces, to ensure maximum confidentiality.

Yes, Magellan Circuits offers expedited services to meet the demands of urgent production runs. We understand that tight timelines are often critical, and we have dedicated processes in place to ensure fast and reliable delivery without compromising quality.

Prioritized Production Scheduling

For expedited orders, we adjust our production schedule to prioritize your project. This ensures that your PCBs are moved to the front of the production queue, significantly reducing lead times.

Streamlined Material Sourcing

We leverage our robust supplier network and premium procurement services to secure critical components quickly. For hard-to-find parts, we use specialized sourcing channels and expedited shipping options to prevent delays.

Flexible Manufacturing Capabilities

Our agile manufacturing processes are designed to accommodate rush orders, including:

• Faster turnaround times for PCB fabrication.
• Optimized assembly workflows to minimize downtime between stages.

Expedited Shipping Solutions

We collaborate with trusted logistics partners to ensure fast and secure delivery. Whether through express courier services or air freight, we select the most efficient shipping options to meet your deadlines.

Consultation for Feasibility

For especially urgent projects, we work closely with you to evaluate feasibility and establish realistic timelines. Our team provides recommendations on design adjustments, material substitutions, or other optimizations to accelerate the process further.

By combining these measures, Magellan Circuits ensures that your urgent production needs are met with speed, precision, and reliability.

Yes, Magellan Circuits can handle kitted or consigned assembly orders, offering flexible solutions to meet your specific requirements. Whether you prefer to supply all or some of the components for your PCB assembly, we adapt our processes to ensure seamless integration into your project.

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Yes, Magellan Circuits offers both IC programming and conformal coating services as part of our comprehensive PCB assembly capabilities.

IC Programming

We provide IC programming services to ensure that integrated circuits are pre-programmed and ready for operation when installed on your PCB.

• Programming Flexibility: We support a wide range of ICs, including microcontrollers (MCUs), FPGAs, EEPROMs, and flash memory.
• Programming Methods: ICs can be programmed through on-board test points or dedicated sockets, depending on your design requirements.
• File Management: Simply supply us with your programming files, firmware, or configurations, and we’ll ensure precise programming with proper verification.
• Batch Programming: Whether you need programming for prototypes or large production runs, we scale our services to meet your needs.

Conformal Coating

We also provide conformal coating services to protect your PCB assemblies from environmental factors such as moisture, dust, and corrosion.

• Coating Types: We work with various conformal coating materials, including acrylic, silicone, urethane, and parylene, depending on your project’s specific needs.
• Application Methods: Our process includes spray coating, brush coating, or dip coating to ensure even and consistent protection.
• Selective Coating: Areas that require electrical contact, such as connectors, are carefully masked off to maintain functionality.

By offering IC programming and conformal coating, Magellan Circuits provides a one-stop solution for ensuring your PCBs are not only functional but also protected against external factors, saving you time and effort in post-assembly processes.

Yes, Magellan Circuits offers comprehensive turnkey solutions that cover the entire process—from PCB design to manufacturing and assembly. Our turnkey services are designed to streamline your project, reduce complexity, and ensure high-quality results.

Turnkey Design Services

Our design team works closely with you to transform your concept into a manufacturable PCB layout.

• Schematic Design: We translate your ideas into detailed circuit schematics.
• PCB Layout: Our experienced designers create efficient layouts that balance performance, cost, and space constraints.
• Signal Integrity (SI) and Power Integrity (PI): We ensure optimal performance for high-speed designs and power distribution networks, addressing critical issues such as crosstalk, noise, and voltage drops.
• Design for Manufacturability (DFM): Every design is optimized for smooth production, reducing the risk of delays or defects during manufacturing.
• Prototyping and Validation: We offer rapid prototyping to test and refine designs before full production.

Turnkey Manufacturing Services

From sourcing components to final assembly, we manage every step of the production process.

• Component Sourcing: We leverage our global supplier network to source high-quality components at competitive prices.
• PCB Fabrication: Our advanced manufacturing facilities handle PCBs of varying complexities, including multilayer and HDI designs.
• Assembly: We use state-of-the-art SMT and THT equipment for precise and reliable assembly.
• Testing and Quality Assurance: All products undergo rigorous testing, including AOI, ICT, FCT, and environmental stress screening, to ensure they meet your requirements.

Advantages of Our Turnkey Solutions

• Single Point of Contact: With all processes managed in-house, you save time and avoid the challenges of coordinating multiple vendors.
• Faster Time to Market: Streamlined processes and close collaboration ensure that your product moves from concept to production quickly and efficiently.
• Cost Savings: Consolidating design, manufacturing, and assembly under one provider reduces overhead costs and minimizes the risk of miscommunication.
• Scalability: Whether you need a small prototype run or high-volume production, our turnkey solutions scale to meet your needs.

By offering end-to-end turnkey solutions, Magellan Circuits enables you to focus on innovation and market strategies while we handle the technical complexities of design and production.