ACC offers a full range of Electronics Manufacturing Services. Please click on the services listed below for details and pictures. Don't forget to scroll down. We offer lots of services!
Surface Mount Assembly is our specialty. ACC has selected robust, reliable, fast, and accurate machines for our Surface Mount Assembly process. Our SMT Lines can be used interchangeably for most projects. See the Soldering and Equipment Pages for more information, pictures and videos.
Compare the spacing between the leads on the two parts in this picture. As electronic components have become smaller and smaller, chip designers have been forced to decrease spacing between component leads.
As a result, solder paste and component placement accuracy have become increasingly critical. ACC can do the job!
In some cases, it was impossible to get enough leads on the edges of components. Ball Grid Arrays and Lan Grid Arrays were solutions, but placement accuracy and temperature control requirements increased. (The component shown has 361 "leads".)
Since connections are made on the under side of the component, visual inspection is virtually impossible. X-Ray inspection is the solution.
ACC still does a lot of through-hole (T-H) assembly for various reasons: some "legacy" and power components are only available in T-H configurations; some customers need the mechanical strength of through-hole connectors; and most of the T-H components we place don't lend themselves to automatic insertion.
The cost of automating the assembly of a few prototype boards is sometimes prohibitive. Hand assembly is the answer. Because of the small size and tight lead spacing of SMT components, experience and microscopes are required.
After prototype approval, a Product Verification Build or "Pilot Run" may be advisable. This step involves a "short run" (25, 50, or 100) of product built under normal production processes using any custom tooling that may be required. Our customers often come to our plant to observe and provide first-article approval. Adjustments (if required) are made, and the pilot run is completed. Field testing may follow. Upon final approval, ACC is ready for "full-blown" production.
Production quantities are quite different for ACC's customers. We build boards that cost thousands of dollars each and have an annual volume in the hundreds. We also build boards with low-dollar values that have annual volumes of hundreds of thousands or even a million units. Regardless of the production quantity, all of our customers are important to ACC.
In-Circuit Testing checks printed circuit boards for shorts and opens, checks the tolerance of components, verifies polarity, and assures that the board has been assembled as specified by the design engineer. Custom test fixtures and test programs are required. Due to the "front-end" investment, in-circuit testing is often chosen for high-value or high-volume boards and assemblies that are used in life-threatening applications.
Functional Testing powers up the product and assures that it is operating properly and providing all the functions specified by the design engineer. In most cases, our functional testers are designed and built by the original design engineer. ACC can also have functional testers built to meet customer requirements.
Following functional testing, some of our customers specify a "burn-in" to prove that the product will continue to function properly over a specified period of time. In some cases, the burn-in is done at elevated temperatures with monitoring equipment attached to record results.
Conformal coating is applied to printed circuit boards that are exposed to harsh environments. ACC normally uses a silicon based coating to protect the board from moisture and dirt.
ACC also provides final assembly services - often referred to as "box builds". This step usually involves assembling the chassis, installing wire harnesses, installing printed circuit boards, and final testing.
ACC custom tailors programs to fit our customers' needs. One project included the following services: forecast production (based on prior year's sales), purchase components, assemble pc boards, final assembly (box build), test, burn-in, re-test, package, inventory finished goods, take orders, drop-ship products, and invoice end users. Payments are remitted to our customer who is responsible for marketing the product.
ACC provides a one-year warranty on our assembly services and passes through the manufacturer's warranty on components. If there is a warranty problem, we fix it.
We also offer Out-of-Warranty Repair for products that we build. This work is done on a time & materials basis. In some cases, we operate a repair depot for our customers. End users ship the product to your company's name at our address. We make the repairs, return the product to the end user, and generate an invoice.
Assistance with Design for Manufacturability is a service provided by ACC. For maximum benefit, it needs to happen early in your design process - well before your printed circuit board layout has been finalized. Our process engineers will examine your board layout in an effort to find simple changes that your design engineer can incorporate to reduce manufacturing cost and improve quality. Expensive solder fixtures are sometimes required to fix simple board layout issues. If our production costs can be reduced, you reap the benefit.
We do have some basic requirements for board layout that are covered in an attached white paper.
We had experience with one board for which the in-circuit test design house could only provide about 65% coverage (access only about 65% of the circuitry). This made the value of in-circuit testing questionable. More recently, we were involved with a board for which the customer's design engineer provided 98% coverage! In the latter case, the test fixture and software are easier to design and the test results are far more reliable.