Through-hole PCB assembly remains an important process for many applications. While SMT has increased in popularity for compact designs, through-hole technology continues to play a crucial role, particularly for electronics products that require larger components and high-powered handling. If you have a high-volume production order and are looking for consistent product quality and reliability, utilizing automated machine insertion techniques can help increase your throughput and efficiency. Let’s look at the four types of automated processes in the electronics manufacturing process that help streamline your assembly: jumper wire insertion, DIP/radial insertion, axial sequencing, and axial insertion.

Jumper Wire Insertion –This process plays a critical role in circuit board assemblies, whether used as part of the original design, for board modifications, or to correct defects. Jumper wires allow printed circuit boards and electronic assemblies to be repaired or modified to ensure electrical continuity between the two sites. Methods of this process are typically based on customary business (customer design) and professional procedures. Since not all jumper wire adds can be automated, at Janco Electronics, we leverage our J-STD certified solderers to handle that process.

DIP Insertion –The Dual Inline Package (DIP) insertion process consists of leaded through-hole components being automatically inserted into the holes of the PCBs and mechanically fixed in place by the under-board clinching of each component’s leads. DIP Insertion Machines can be either manual or automatic. Manual DIP Insertion Machines require the operator to manually load the components into the machine and to monitor the machine during operation. Automatic DIP Insertion Machines can be programmed to load and place the components automatically.

Axial Component Sequencing –Electronics Manufacturers can reduce assembly time by sequencing their axial components prior to running them through the Axial Insertion Machine. The Axial Sequencing Machine arranges components in a precise order on carrier tapes, designed to align with your PCB assembly specifications. Pre-sequencing components allows the EMS to boost production assembly, minimize potential errors, and reduce costly mistakes and rework. There are very few Electronics Manufacturers that still utilize a Sequencing Machine. Those that don’t have the equipment will manually place all through-hole components and rely on their hand assembly teams to form, place, trim, and solder axial components to the circuit boards.

Axial Insertion –During this process, axial leaded through-hole components are taken from pre-sequenced reels and fed into dispersing heads, which cut the parts onto a chain in order of insertion. The components get transferred from the sequence chain to an insertion chain, bringing the component underneath the insertion head. The insertion head cuts the components’ leads to the proper length (for lead length and insertion span), bends the leads 90 degrees, and then inserts the component leads into the board while a clinch assembly takes place. From here, the boards move to the wave solder machine where all the placed components get soldered at once.

It is no secret that automation provides the electronics manufacturing industry with many benefits. With the growing popularity of board miniaturization and Surface Mount Technology, printed circuit board designs are using less through-hole components and more Surface Mount components. Electronics Manufacturers that continue to work in the defense and aerospace sectors still benefit from machine insertion. Many PCBs built for the military still utilize through-hole components because they can continually withstand and operate in harsh environments. For those boards that use through-hole components, Automated Insertion allows for consistent quality and quantity, ensures high throughput and efficiency, and even provides inventory management, effectively driving down labor costs and rework while improving the production process.

So why isn’t Electronics Manufacturing fully automated at this point? For now, the cost of automation requires a very large capital investment and the ever-changing product designs due to technological advancements would require constantly updating those fully automated systems which, in turn, costs more money. In addition, full automation is designed for large-scale, standardized production so the massive variability of components and assembly processes for more customized assemblies still requires manual intervention. Electronics Manufacturers that employ both automated and manual processes strike a better balance, allowing them to minimize costs while maintaining high standards for product quality. At Janco Electronics, we offer both manual and automated PCB assembly. We have the equipment and capability to build your PCB to your specifications and deliver a high-quality product that exceeds your expectations.