Mid Volume PCB Assembly Manufacturer for Reliable Production Runs

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ISO 9001/UL Certified
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PCB Assembly Specialists
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97% of PCB Shipped on Time
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98% of PCB Delivered to Spec
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Delivery Guarantee

What is Mid Volume PCB Assembly?

PCB Manufacturing Process

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Mid Volume PCB Assembly Manufacturer Delivering End-to-End Production Expertise

What are Our Mid Volume PCB Assembly Capabilities?

Specification PCBA Capability
Placer speed 600,000 chips/hour
Lead Time 25+ Days (To Be confirmed)
SMT SMT, Through Hole Assembly
Single/Double-Side SMT, Single/Double-Sides Mixture Assembly
PCB Size 50mm×50mm ~610mm×508mm
PCB Thickness 0.5mm~4.5mm
Min. diameter /space of BGA 0.2mm/0.35mm
Qualifications ISO 9001:2015
Accuracy <±30µm, under the condition of 3σ,CPK≥1
Minimum width/space of QFP 0.15mm/0.25mm
Minimum Diameter /Space of BGA 0.2mm/0.35mm
Reliability Test Flying Probe Test/Fixture test, Impedance Test, Solderability Test, Thermal Shock Test, Hole Resistance Test, and Micor Metallographic Section Analysis, etc.
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Specification PCBA Capability
Placer speed 600,000 chips/hour
Lead Time 25+ Days (To Be confirmed)
SMT SMT, Through Hole Assembly
Single/Double-Side SMT, Single/Double-Sides Mixture Assembly
PCB Size 50mm×50mm ~610mm×508mm
PCB Thickness 0.5mm~4.5mm
Min. diameter /space of BGA 0.2mm/0.35mm
Qualifications ISO 9001:2015
Accuracy <±30µm, under the condition of 3σ,CPK≥1
Minimum width/space of QFP 0.15mm/0.25mm
Minimum Diameter /Space of BGA 0.2mm/0.35mm
Reliability Test Flying Probe Test/Fixture test, Impedance Test, Solderability Test, Thermal Shock Test, Hole Resistance Test, and Micor Metallographic Section Analysis, etc.
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Comprehensive AOI and Functional Testing

Inline automatic optical inspection (AOI) captures high-resolution 2D and 3D imagery to detect missing components, tombstoning, skew, and insufficient solder joints with a detection accuracy exceeding 95%.

Post-assembly functional testing verifies power integrity, I/O response, and operational logic, helping clients in critical fields like medical monitoring and telecommunications validate every board before final shipment.

Full BOM Sourcing and Hard-to-Find Components

OurPCB handles full BOM sourcing through authorized distributors, ensuring traceability down to date and lot codes for critical parts. For hard-to-find electronic components or end-of-life risks, our sourcing teams propose form-fit-function alternatives with full client approval workflows, maintaining compliance with IPC standards and safeguarding continuity in low-mid volume production and scaling phases.

Custom Fixtures and Dedicated Testing Solutions

Custom ICT and functional test fixtures are designed in-house to match specific board layouts, providing up to 500 test points for comprehensive validation. Fixture-guided testing reduces operator variability, improves first-pass yield rates by up to 10%, and accelerates fault isolation, a sizable advantage when scaling from prototype quantities into sustained mid volume PCB assembly runs.

How does OurPCB Handle Mid Volume Production Runs?

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What does the Mid Volume PCB Assembly Process Include?

PCB Fabrication and Material Preparation

Mid-volume production begins with internal PCB fabrication, where printed circuit boards are manufactured to precise Gerber specifications, often incorporating controlled impedance, blind/buried vias, or HDI features for complex designs.

Material selection, such as FR4, Rogers, or polyimide, is verified, and moisture-sensitive boards are stored in drying cabinets under strict humidity control to prevent delamination or popcorning defects during assembly.

Stencil Preparation and Solder Paste Application

Custom laser-cut stencils are created based on pad design and solder volume calculations.

Solder paste is applied using automated printers equipped with 2D paste inspection systems, followed by SPI measurements checking paste height, volume, and offset tolerances within ±10%.

Early misalignment detection at this stage prevents underfill defects and opens in fine-pitch assemblies.

Surface Mount Placement and Reflow Soldering

Components as small as, 01005 packages and fine-pitch BGAs are placed using high-speed pick and place machines, achieving positional accuracy within ±40μm.

Boards then enter nitrogen-assisted reflow ovens, where optimized profiles minimize voiding and thermal stress, particularly important for high-density assemblies in industrial controls and medical monitors.

Through-Hole Insertion and Selective Soldering

For mixed-technology boards, through-hole components are inserted manually or robotically, depending on production volume and part size.

Selective soldering machines apply precisely directed molten solder, maintaining thermal integrity for adjacent SMT components and preventing bridging issues common in dense connector regions.

Inspection, Cleaning, and Conformal Coating

After soldering, inline AOI systems perform 2D/3D inspections checking for tombstones, bridges, open joints, and polarity errors with >95% detection accuracy.

Boards then move through aqueous or semi-aqueous cleaning systems to eliminate flux residues.

If required, selective conformal coating protects circuits against moisture, dust, and chemical exposure, which is necessary for outdoor electronics and automotive modules.

Final Testing and Quality Verification

Assemblies undergo functional testing using custom-designed fixtures, verifying I/O functionality, power distribution, and timing stability under real-world loads.

X-ray analysis detects hidden solder defects under BGAs and other bottom-terminated components, achieving void detection sensitivity below 25% pad area per IPC-A-610 guidelines.

Final visual inspection under microscopes confirms cosmetic quality before protective packaging and shipment.

Millions of business and innovators use OurPCB

PCB Board Process

Order Received

  • Component Procurement
  • Preparation
  • PCB Manufacture
  • Make Process Flow

Soldering

  • Solder Printing/Wave Soldering
  • SMT/Plugging
  • Inspection (repair if necessary)
  • AOI (repair if necessary)
  • Transfer

Parts Assembly

  • Manual Assembly
  • Cleaning
  • Wire Screw
  • Inspection
  • Repair If Necessary

Finalization

  • Final Confirmation
  • Packing
  • Shiping

Mid Volume PCB Testing and Inspection Process

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SPI Solder Paste Inspection

Solder paste deposits are checked using SPI systems that measure height, volume, and pad coverage before placement begins.

OurPCB maintains ±10% tolerance thresholds on solder volume to prevent defects like head-in-pillow and insufficient wetting during reflow.

Early-stage inspection ensures that only boards meeting print quality standards continue through the assembly process.

Automatic Optical Inspection (AOI)

After reflow, automatic optical inspection scans each board to detect missing parts, polarity errors, tombstoning, skew, and solder bridging.

OurPCB uses both 2D and 3D AOI, allowing volumetric analysis of solder fillets and component seating alongside surface visual checks.

Inspection data feeds directly into production traceability records for real-time yield monitoring.

Why Choose OurPCB as Your Mid Volume PCB Assembly Manufacturer?

Mid Volume PCB Assembly Manufacturer FAQs

What PCB sizes, and layer counts can you handle for mid-volume production?

We manufacture PCB assemblies ranging from 50 mm x 50 mm modules to panels up to 610 mm x 508 mm, supporting 1 to 50-layer stack-ups. Controlled impedance, HDI structures, blind and buried vias, and mixed-material builds are available for mid-volume runs, meeting technical requirements across sectors like medical imaging, automotive sensors, and industrial automation.

Can you manage both SMT and through-hole components on the same board?

Yes, OurPCB configures hybrid SMT and through-hole assembly lines to support mixed-technology designs. Boards combining 0201 SMT parts, connectors, and power components up to 20A ratings are processed using selective soldering with nitrogen atmospheres, preventing thermal stress and improving mechanical stability for mission-critical applications.

How do you control solder quality during mid-volume production?

Solder paste deposition is verified with 3D SPI systems within ±10% volume tolerance, followed by real-time AOI and X-ray inspections after reflow. SPC techniques track variation trends, triggering process adjustments before defects propagate. These controls maintain first-pass yields above 98% across mid-volume production batches.

What types of PCB testing are available before shipment?

Every PCB assembly passes inline automatic optical inspection and receives functional testing with programmable fixtures simulating operational conditions. For boards with complex or hidden interconnections, in-circuit testing (ICT) and 3D X-ray verification are applied. Testing strategies are customized based on application criticality, regulatory needs, and expected operating environments.

Can you support PCB prototype assembly before scaling to mid-volume production?

Yes, OurPCB offers prototype PCB assembly services with the same certified processes used for full production. Early-stage builds benefit from DFM and DFT analysis, allowing clients to identify manufacturability or testability risks before ramping into low-mid volume production. Seamless scaling reduces project lead times and stabilizes quality performance across volumes.

Partner with OurPCB for Reliable Mid Volume PCB Assembly Manufacturer Services

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