At Protronix EMS, we deliver high-reliability PCB assembly services from our dedicated facility in Luton. We support UK manufacturers with flexible electronic manufacturing services (EMS), bridging the gap between fast-turnaround prototyping and scalable volume production.
Our assembly teams work strictly to the IPC-A-610 acceptability standard. This ensures that every solder joint, component placement, and mechanical fixture meets the rigorous quality levels required for mission-critical applications in industrial control, sensing, scientific and a host of other sectors.
Our Assembly Capabilities
We operate a flexible manufacturing floor designed for high-mix requirements. Whether your design utilises the latest miniaturised footprints or requires robust manual assembly, we have the infrastructure to deliver.
- Surface Mount Technology (SMT): High-speed, automated placement for complex architectures, including fine-pitch ICs, BGAs, and passives down to 0201.
- Through-Hole Assembly: Expert manual soldering and wave soldering for ruggedised components, connectors, and power electronics.
- Mixed Technology: Seamless integration of SMT and Through-Hole components on a single PCBA, managing the unique thermal profiles required for double-sided boards.
The Assembly Workflow
We believe that process control is the foundation of quality. Our workflow is designed to minimise handling and maximise traceability.
1. Pre-Production Engineering & Procurement
The process begins before the first component is placed. We perform a comprehensive review of your Bill of Materials (BOM) and Gerber files. Our procurement team verifies component availability to mitigate supply chain risks, while our engineers review the PCB layout for manufacturability (DFM) to prevent production stoppages.
2. Solder Paste Printing
Precision starts at the base level. We utilise high-quality stencils and automated paste printing to ensure the correct volume of solder paste is deposited on every pad. This stage is critical for preventing bridging or dry joints later in the process.
3. Pick & Place (SMT)
Our automated SMT lines populate boards with speed and accuracy. The machines utilise intelligent vision systems to align components perfectly, handling everything from standard resistors to complex QFNs and BGAs.
4. Reflow Soldering
Boards pass through our multi-zone reflow ovens. We utilise carefully developed thermal profiles that ensure the solder reaches the optimal liquidous state without subjecting sensitive components to thermal shock.
5. Manual Assembly & Wave Soldering
For through-hole components, we employ skilled operators trained to IPC-A-610 standards. Depending on the volume and board complexity, components are soldered via automated wave soldering machines or by hand for precision requirements.
6. Inspection & Quality Control
We do not rely on spot-checks. We employ a rigorous inspection regime tailored to the board’s complexity:
- Visual Inspection: Magnified inspection by trained staff to verify component orientation and solder fillet quality.
- Inspection Techniques: We utilise advanced inspection methods to verify production quality, ensuring consistency across the batch.
- IPC-A-610 Compliance: Every board is inspected against the visual criteria of the IPC-A-610 standard to ensure acceptability.
7. Cleaning & Finishing
To ensure long-term reliability, particularly for boards destined for harsh environments, we process PCBAs through wash cycles to remove flux residues. This leaves the PCB chemically clean and free from dissolved solids, thanks to monitored rinse stages, ready for conformal coating or final box build assembly.
Technical Specifications
| Capability | Specification |
|---|---|
| Component Size | Down to 0201 (Imperial) / 0603 (Metric) |
| Component Types | To include BGA, µBGA, QFN, DFN, SOIC, PLCC, Connectors |
| Board Types | Rigid, Flex, Rigid-Flex, Metal Core (IMS) |
| Solder Types | Leaded and Lead-Free (RoHS Compliant) |
| Standards | IPC-A-610, ISO 9001 Certified |
| File Formats | Gerber, BOM (Excel/CSV/PDF), Placement Data (Excel/CSV) |
The full array of PCB boards, for every PCB assembly use case
Single-sided PCBs
Double-sided PCBs
Multilayer PCBs
Rigid PCBs
Flexible PCBs
Rigid-Flex (Hybrid) PCBs
LED PCBs
HDI PCBs
All of our boards are sourced from UL-approved PCB board fabricators.
SMT (surface-mount technology)
A PCB assembly technique well suited to smaller components, higher density and greater volumes.
SMT has become the industry standard for most PCB assemblies nowadays.
Each component is surface-mounted on solder paste and soldered using the reflow technique.
THT (through-hole technology)
Sometimes hand-placed, or sometimes placed by our machines, this PCB assembly technique involves directing each component’s metal wires through holes.
These are then wave-soldered (also known as flow soldering) from the other side to terminate them.
Why Partner with Protronix EMS?
Flexible Production Volumes
We do not impose rigid Minimum Order Quantities (MOQs). We are optimised for:
- Prototyping: Fast turnaround for design verification.
- Small to Medium Volume: Agile batch production for specialised markets.
Full Turnkey Solutions
Reduce your administrative burden by letting us handle the supply chain. We source all components, PCBs, and mechanical parts, delivering a “file-to-finished” solution that arrives at your door ready for use.
Ready to Quote?
Get a detailed quote for your PCB assembly project. Send your Gerber data and BOM to our engineering team today.
Case Studies: UK PCB Assembly Services
When a specialist lighting manufacturer required an additional batch of LED panels producing, outside of their existing suppliers fixed schedule, they came to us.
Our automated high speed SMT line quickly processed these boards. LED panels are typically densely populated, this is where placement speed counts.
We were able to assemble these boards far quicker than the original supplier. This meant not only could we meet the required delivery date, but we could lower the customers costs too. As a result, ongoing production requirements were transferred to us.
Having experienced less than acceptable yields on their product, a studio grade audio manufacturer entrusted us to build a batch of boards for them.
The boards were assembled to IPC-A610 acceptance standards… as standard. The customer reported a 100% acceptance rate upon test, this was something they had not experienced before.
What the cause of their previous issues were, is not known to us, but sourcing genuine quality parts from our established supply chain and building product to the highest acceptance standards, surely contributed to the 100% acceptance rate of the product we supplied.
If you’ve got questions then now is the right time to ask them. Get in touch with our team today or send us your specifications to [email protected].
