Authored by Pankhuri

In the highly competitive electronics manufacturing industry, integrating printed circuit boards (PCBs) into a final product, known as box build assembly, is a complex process fraught with challenges. From intricate design requirements and supply chain disruptions to stringent quality standards and capacity constraints, each stage presents unique obstacles that can impact timelines, costs, and overall product quality. 

Understanding and effectively addressing these common challenges is crucial for ensuring smooth production flows, maintaining high standards, and meeting market demands. Let’s explore the most prevalent challenges in PCB assembly for electronics box build projects and go through actionable strategies to overcome them.

Soldering Defects

PCB soldering defects are a common issue in PCB assembly, including gaps in solder joints, cold solder joints, solder balling, solder bridging, component shifts, lifted pads, webbing, splashing, sunken joints, tombstoning, and shadowing. These defects can range from cosmetic issues to functional failures. Severe defects may require scrapping the entire board, causing significant delays. Detecting a soldering defect necessitates stopping and fixing the process, which increases assembly costs and delays delivery timelines. 

How to mitigate?

To prevent soldering defects, a design review before assembly can identify potential problem areas. Prevention is the best solution, and an ECM that proactively approaches PCB design and maintains a rigorous testing program can help overcome these challenges.

Improper Component Placement

Placing components too close together, incorrectly oriented, or in the wrong location on the board can cause issues during manufacturing. Component placement is crucial to the PCB manufacturing process, and improper placement can significantly increase costs. To avoid this,

How to mitigate?

The board should undergo a DFM (Design for Manufacturing) analysis before assembly. This analysis helps in selecting the right components and optimising their placement.

Board Warping

Board warping refers to the unintended alteration of a PCB’s shape, causing assembly issues. When a PCB warps, it doesn’t stay flat, leading to inconsistent height and construction problems as the device is assembled. Warping can result in poor solder joints and potential damage to components. Even if assembly is possible, a warped PCB can lead to project failure. 

How to mitigate?

Addressing board warping early is crucial. To prevent warping, maintaining balance in the board design is essential. During construction, technicians should avoid applying excessive heat or force, particularly in thinner areas. An experienced manufacturing team that knows how to prevent board warping can effectively eliminate this issue.

Mitigating Electrical Noise in PCB Assembly

Electrical noise is often generated by poor PCB design. While some noise is acceptable if it doesn’t interfere with system performance, improper handling can impact board operation. High-frequency noise, in particular, can degrade performance and is often caused by spikes in electrical signals due to incorrect ground connections. 

How to mitigate?

Effective PCB layout is essential to mitigate this issue. Proper layer arrangement can significantly reduce electrical noise, and incorporating ground planes into the PCB design can help cover the board area and minimise noise. A skilled design team can work during the design phase to ensure electrical noise is kept to a minimum, ensuring optimal board performance.

PCB Assembly Services with is your one-stop solution to cater to all your electronic manufacturing requirements. With a network of 500 vetted and certified suppliers nationwide, well-versed in the intricacies of electronics integration and are trusted by top-tier companies, assuring you of optimal results!

Why do we stand out?

  • Turnkey and contract manufacturing solutions
  • Dedicated assembly lines for high-volume PCB assembly
  • Global Sourcing of raw materials
  • Integrated Quality Management System

Our flexible manufacturing services enable product efficiency and quality across orders of all sizes from small batches to large volumes, while offering box build solutions along with product localisation capabilities.

If you’re looking for an EMS provider that meets the technical capabilities, contact us today. Let us help you reach the optimal outcome for all your manufacturing requirements. To get started, simply email Pushpalaxmi Vanniyar at with your specifications or fill out the form below.