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Manual Soldering Vs. Automated Soldering In Electronic assembly

Introduction

Soldering is a critical process in the assembly and manufacture of electronic devices and PCBs. It provides both mechanical and electrical connections between component leads and pads. While manual soldering has been used for decades, automation through machines and robots has become essential for modern high-volume production.

This article will compare manual and automated soldering approaches across criteria like process capabilities, quality, costs, applications, advantages, and disadvantages. We will examine popular techniques including manual iron soldering, wave soldering, selective soldering, and automated soldering robots. Understanding the strengths and limitations of each method helps determine the best fit for a particular manufacturing environment and product.

Manual Soldering Techniques

PTH Soldering
PTH Soldering

Manual soldering relies on a human operator to directly form joints using a hand-held soldering iron or soldering station. Let’s look closer at manual techniques.

Soldering Irons

The most basic manual approach uses simple electrical or battery-powered soldering irons.

How It Works

  • Apply solder tip to heat metallic surfaces
  • Flow solder onto heated area to form joint
  • Remove iron once joint solidifies

Capabilities

  • Versatile for prototyping and rework
  • Accessible for small joints and SMD components
  • Portable and inexpensive

Limitations

  • Very low production throughput
  • Operator skill dependent
  • Fatigue and human error risks

Best For

  • Low volume assembly
  • Labs and repair work
  • Precision hand-soldering

With practice, skilled operators can produce high quality solder joints. But throughput is extremely low.

Soldering Stations

More advanced solder stations offer temperature control, flexible tips, and easier use.

How They Work

  • Station controls tip temperature
  • Apply heated tip to melt solder
  • Pedals and stands aid ergonomics

Capabilities

  • Excellent for precision and rework
  • Reduce operator fatigue
  • Tip temperature and profiles help joint quality

Limitations

  • Throughput still very low
  • Long learning curve for operator skill

Best For

  • Medium complexity assemblies
  • Maintenance and rework stations
  • Operators performing long soldering sessions

Solder stations make intensive manual soldering more ergonomic and efficient.

Wave Soldering

Wave soldering flows a wave of molten solder over assembled boards to simultaneously solder all components.

How It Works

  • Bottom of board with inserted components passes over solder wave
  • Solder wets to metallic surfaces completint joints
  • Parameters like conveyor speed tightly controlled

Capabilities

  • Very fast, efficient for high volumes
  • Joints form simultaneously
  • Consistent process for reliability

Limitations

  • High equipment cost
  • Limited to through-hole components
  • Shadowed joints may be problematic

Best For

Wave soldering excels at fast production of through-hole boards.

Automated Soldering Methods

PCB Assembly Introduction

Now let’s examine automated soldering techniques that leverage machines or robotics.

Selective Soldering

Selective solder machines target only specific joints to be soldered.

How It Works

  • Bottom board preheats on conveyor
  • Miniature solder nozzle dispenses solder only on selected joints
  • Other areas masked to limit solder flow

Capabilities

  • Automates process for speed and repeatability
  • Avoids disturbing sensitive components
  • Selectively solders target joints only

Limitations

  • Additional fixturing and preparation time
  • Only suitable for select joint types
  • Generally lower throughput than wave

Best For

  • Mixed SMT and through-hole assemblies
  • Re-soldering defective joints
  • Debugging and rework stations

Selective systems provide automated precision and flexibility.

Robotic Soldering

Industrial robots can be programmed to precisely solder components and wires using specialized heads and grippers.

How It Works

  • Robots equipped with soldering irons or mini-waves
  • Precision movement solders targets along programmed path
  • Advanced vision guides for complex assemblies

Capabilities

  • Extremely flexible for handling variety
  • High precision and repeatability
  • Scalable by adding robots

Limitations

  • High equipment and programming cost
  • Cycle times can be slower than fixed automation

Best For

  • High mix, low-mid volume production
  • Challenging geometries requiring articulation
  • Applications unsuitable for custom machinery

Robotic soldering adds unmatched flexibility to automation.

Laser Soldering

Focused laser energy can be applied to form reliable solder joints without contacts.

How It Works

  • Laser pulse rapidly heats joint area
  • Apply solder preform or paste to bond surfaces
  • Laser energy absorbed by joint finishes

Capabilities

  • Contactless, no tip wear or cleaning
  • Precise localized heating
  • Used on heat-sensitive components

Limitations

  • Expensive laser optics and power needed
  • Limited penetration depth
  • Generally slower than traditional methods

Best For

  • Microelectronic assemblies and repairs
  • Soldering to temperature-sensitive devices
  • Joints requiring perfect cosmetic appearance

Lasers form high quality joints without contacting or overheating components.

Criteria Comparison

Let’s compare manual and automated soldering across some key criteria:

Applications and Selection

Now let’s look closer at typical applications where manual and automated soldering may be preferable and why.

When Manual Soldering Excels

Manual soldering with an iron is advisable for:

Low Volume Production

  • Not economical to set up automation for small lots

Complex, Variable Assemblies

  • Robots cannot easily handle one-offs and new designs

Inspection During Assembly

  • Allows verifying each joint when formed

Accessing Confined Spaces

  • Iron tips can reach into tight spots automation can’t

Quick Design Changes

  • Engineers can manually modify prototypes easily

Minimal Upfront Investment

  • Inexpensive irons/stations vs. six-figure machinery

For short runs, prototypes, and R&D flexibility, manual methods prevail.

When Automated Soldering is Preferred

Automated systems excel for:

High Volume Manufacturing

  • Consistent throughput 24/7 with minimal labor

Maintaining Repeatability

  • Tuned processes ensure the same precision daily

Hazardous/Tedious Work

  • Removes workers from hot, fume-filled environments

Reducing Defects

  • Automated inspection and correction lowers errors

Meeting Quality Requirements

  • IPC standards and extra process control

Balancing Loads

  • Levels production flow between lines and shifts

Automating soldering is mandatory for large scale, high reliability manufacturing.

Combining Manual and Automated

In practice, a combination of manual and automated soldering will serve most production environments best:

Low-Mid Volume

Use manual soldering for:

  • Short runs
  • Quick changeovers
  • Small rework

Use selective automation for:

  • Improved throughput
  • Critical joints
  • Repeated assemblies

High Volume

Use automated soldering for:

  • Main production runs
  • Maximum throughput

Use manual soldering for:

  • Prototyping
  • Programming machines
  • Exception handling

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