Core PCB Assembly Capacity
- SMT & THT and Complete Unit Assembly: Supports single-sided, double-sided, dual-side, and through-hole operations for PCBs.
- Precision Handling of Fine-Pitch Components: CONSONS can handle ultra-small components such as 01005 and 0201 in packaging formats like QFN and BGA.
- Advanced Soldering Capabilities: CONSONS offers the following soldering methods: nitrogen reflow soldering, wave soldering, or selective soldering..
- Conformal Coating: We provide waterproof, moisture-proof, and corrosion-resistant coatings for outdoor and medical environments.
- Functional and Aging Testing: We can provide custom fixture development or functional load testing, etc.
- Complete Unit Assembly: With our in-house injection molding facility, we offer finished product assembly services.
Why You Can Trust CONSONS PCB Assembly Services
CONSONS is a professional PCBA service provider and EMS manufacturer based in China. We have over twenty years of experience in PCB assembly. Our PCB assembly services include DFM and DFT, which can help you optimize your circuit board design.
Moreover, thanks to our established global supply chain, we can secure the most competitive component procurement costs for you. Every PCBA undergoes strict quality and performance testing before shipment, and only those that meet our quality standards are delivered to your location.
Types of CONSONS PCB Assembly Services
Our full-service solution covers the entire process from PCB manufacturing and component procurement to SMT assembly, testing, and packaging. All you need to provide is a BOM and Gerber files.
You provide core components such as chips, and CONSONS will handle the procurement of generic components.
You provide the materials, and CONSONS provides only SMT placement, AOI and X-ray inspection, and testing.
Benefits of CONSONS PCB Assembly Services
Through the integration and collaboration of our global supply chain, we can reduce the total cost of component procurement by 18%.
CONSONS can support small-volume orders of 1,000 pieces as well as large-volume orders of tens of thousands of pieces.
By integrating global material supplies, we can provide alternative material options for your chips, ensuring stable material procurement and supply.
Through our MES system, quality traceability covers the entire process from incoming inspection and material procurement to SMT placement, PCB assembly.
Precision Surface Mount Assembly
For precision PCB structures and layouts, CONSONS uses high-precision automated placement machines to ensure the accuracy of fine component placement. Our automatic production lines are able to achieve a precision of up to ±0.05 mm. This effectively prevents placement misalignment from affecting the performance and functionality of your PCBA.
Optimized Stencil Design
We support precise adjustment of stencil aperture sizes and customization of thickness to ensure a precise fit with component pad dimensions. Taking fine-pitch components with a pitch of 0.5 mm as an example, CONSONS maintains a 1:1 ratio between the aperture size and the pad size to ensure optimal soldering results. This also ensures uniform solder paste application and helps prevent defects such as solder bridges and solder balls.
Precise Reflow Soldering Temperature Control
During the reflow soldering process, we maintain the temperature of the lead-free solder at the peak of the curve at 245°C. This precise temperature control prevents the problem caused by the induced stress, like fractures or board warping. Therefore you will receive more uniform PCBAs.
China Turnkey PCB Assembly Supplier
- 20,000-square-meter factory.
- 10 SMT production lines + 7 THT lines + AOI + X-ray.
- IATF 16949, ISO 13485, and ISO 9001 certified.
- Production Capabilities: Precision SMT assembly, BGA/QFN packaging, 3D X-ray inspection, ICT/FCT testing, thermal cycling testing, EMC optimization.
- Short Lead Time: 2–3 days for prototypes, 1–2 weeks for trial orders, and 3–4 weeks for mass production.
Certified PCB Assembly Applications
CONSONS’ PCB assembly services are also applicable to the aerospace sector. We are AS9100-certified and can manufacture PCBs for spacecraft control, radar, and communications systems. For harsh operating environments, we also offer processes such as conformal coating.
CONSONS holds ISO 13485 certification for medical systems. Our cleanroom assembly facilities ensure the cleanliness of PCB assembly and the accuracy of data transmission during subsequent use, guaranteeing the precision and reliability of medical applications. Our services are suitable for a wide range of critical medical devices, including patient monitors and imaging scanners.
In the automotive electronics sector, CONSONS is certified to IATF 16949 and can provide PCB assembly for battery management and motor control systems, meeting the vibration resistance and temperature tolerance requirements of automotive applications.
Smart applications place high demands on the signal transmission integrity of PCB assemblies. CONSONS ensures the integrity of signals received by PCBA through high-precision placement of micro-components such as 01005 parts, guaranteeing smooth operation of smart devices.
In high-voltage and high-current applications, CONSONS comprehensively guarantees the integrity and manufacturing precision of PCBA components. Insulation and withstand voltage tests are conducted before the PCBA leaves the factory to ensure it can support high-power and high-load applications.
Our PCBA is specially built for extreme conditions in industrial environments, CONSONS provides comprehensive quality control for your PCBA through conformal coating, aging tests, and FCT testing, ensuring it can withstand severe corrosion, humidity, and high-temperature environments.
Quality Inspection for PCBA
During the AOI inspection phase, CONSONS performs inspections using high-resolution cameras and advanced algorithms. AOI can detect component defects as small as 0.1 mm to identify misalignment and other issues on the PCBA.
X-rays can penetrate the circuit board to accurately assess the internal condition of component solder joints. This method is used to inspect the interior of BGA and QFN solder joints, and it can accurately detect even micro-voids as small as 1 μm.
Specifications
- PCBA Assembly & Surface Mount Capabilities
- SMT & DIP Capacity
| Item | Capacity |
| Layers | 1-30, FPC: 1-8 layers |
| Thicker Copper | 1-6 OZ |
| Min Component Size | 01005 chip/Min BGA/QFP pitch:0.3mm |
| Min BGA / QFP Pitch | 0.3mm (With 3D X-Ray Inspection) |
| SMD Placement Accuracy | ±0.03mm (or ±0.05mm) |
| PCB Dimensions | Min: 50×50×0.05 mm Max: 510mm x 460 × 4 mm |
| Soldering Environment | Nitrogen Reflow Soldering |
| Assembly Standards | IPC-A-610 Class 2 / Class 3 |
| Special Processes | Conformal Coating , Selective Wave Soldering |
| Base Material | FR4(Shengyi China, ITEQ. KB At.HZ), HI-TG. FR406. Rogers, Taconic. Arlon and so on |
| Finished Surface | Conventional HASL.Lead-free HASL,Flash Gold, ENIG (Immersion Gold)OSP(Entek). Immersion |
| Inspection & Testing | 3D SPI (Solder Paste Inspection), 3D AOI, 3D X-Ray Inspection, ICT, FCT, Flying Probe, Thermal Cycling |
| Traceability | Full MES barcode tracking (from incoming material batch to SMT pad & FCT record) |
| Product Types | Qty | Normal lead time | Quick-turn lead time |
| SMT | 5-200 | 2ED | 24H |
| SMT | 201-2000 | 3-5ED | 2WD |
| SMT | ≥2000 | 6WD | 3WD |
| SMT+DIP | 5-200 | 3WD | 2WD |
| SMT+DIP | 201-2000 | 5WD | 4WD |
| SMT+DIP | ≥2000 | 7WD | 5WD |
Order Process
First, CONSONS will evaluate the PCB board circuit diagrams, Gerber files, and bill of materials (BOM) you provide to conduct DFM/DFT analysis and offer optimization recommendations. You will receive the DFM report and quote within 24 hours.
Next, we will purchase the required components from qualified distributors, and perform incoming inspection on the procured materials, including checks for purity, quality, and other aspects.
For the placement and assembly of PCBs that require imaging, this step is carried out on fully automated production lines in a cleanroom. Once component assembly is complete, rigorous 3D AOI and X-ray inspections are performed to ensure assembly quality and subsequent performance.
Once assembly is complete, CONSONS will perform FCT testing and aging verification to ensure performance. This step includes firmware programming, automated ICT/FCT functional testing, as well as thermal cycling and EMC verification.
At this stage, your PCBA will be packaged and shipped. You will receive a PCBA that has undergone comprehensive quality and performance control. At the same time, X-Ray/FCT test reports will be provided.
Generally, the cost of PCB assembly services includes stencil fees, component procurement, and assembly labor. This also depends on the type of service you purchase (full-service or partial-service). CONSONS can provide you with a fully transparent breakdown of costs.
The Bill of Materials (BOM) you provide must include essential details such as component type, dimensions, quantity, and required packaging. CONSONS supports file formats including XLS and CSV.
Since these components are difficult to mount and can cause noise and short-circuit issues if broken, CONSONS uses high-speed placement machines equipped with low-force heads during the placement process. Additionally, during the panel separation stage, we employ automatic milling cutters to ensure fast and precise operations, preventing incomplete separation caused by board tearing.
To mitigate the risk of these large components detaching, CONSONS implements reinforcement measures. In addition to SMT placement, we use adhesive dispensing to secure the components. Furthermore, pre-shipment impact testing verifies the stability of these component installations, ensuring their long-term reliability in automotive applications.
The nitrogen reflow soldering process can reduce the contact between PCBA and the oxygen, to prevent the oxidation during the process. Wave and selective soldering can ensure a more precise soldering of specific components to prevent the solder overflow.