The completion of PCB assembly isn't the end of electronics assembly services of PCBONLINE - PCBONLINE provides comprehensive PCBA tests and value-added services in the post-assembly stage. During post-assembly, we use custom-designed PCBA functional testers to ensure PCBAs work as intended, which is crucial for quality control.
What is a PCBA Functional Tester?
A PCBA functional tester is a functional test (FCT) fixture, which is custom-designed and made for the PCBA. It simulates a product's working environment. It performs button, signal, and voltage tests.
The PCBA functional test is after PCBA assembly and in-circuit testing. PCBA functional testers are essential for mid and high-end applications, which PCBONLINE has served for the past 20 years.
PCBA functional testers are also vital for batch PCBA manufacturing. High-reliability PCBAs, including PCBAs with microcontrollers, IoT devices, medical PCBAs, automotive PCBAs, and industrial controls, all require using them.
PCBA functional testers offer significant advantages. They ensure optimal PCBA performance. They prevent human test errors. Test consistency is guaranteed. This is especially true for mass production.
Key Features of PCBA Functional Test Fixtures
PCBA functional testers have several parts.
- Structural components: These include an aluminum profile frame. There is also an acrylic panel. Positioning pins and a pressure plate are present.
- Electrical interface: This involves Pogo Pins. Connecting wires, sockets, and relays are used.
- Control unit: An MCU (microcontroller unit) is central. A switching power supply provides power. A USB interface and PLC (programmable logic controller) are included.
- Host software: This controls automated testing. It handles data recording. Report output is also managed.
PCBONLINE's Custom PCBA Functional Testers
The one-stop PCBA manufacturer PCBONLINE can custom-design PCBA functional testers according to the PCBA. Our clients can provide us with the testing file, but if not, it's also okay, as we can handle the testing process and fixture designs.
However, the PCB Gerber file, the Bill of Materials (BOM), and manufacturing/testing requirements are needed from our clients. In the Gerber file, it's better to include an XY file with PCBA test points.
Based on the above files, PCBONLINE designs the PCB manufacturing and assembly fixtures, including the PCBA functional tester. We don't manufacture the fixtures, but maintain long-term cooperation with the top 3 fixture/mold manufacturers in China, who accurately make the PCB fixtures according to our design and requirements.
PCBONLINE provides free, professional DFM (Design for Manufacturing). It covers PCB, PCBA, and box builds, and includes checking test files and providing all the engineering files needed for electronic manufacturing. This ensures manufacturability and project success.
Cost of PCBA functional testers
Generally, a fixture fee is separate from assembly costs. However, PCBONLINE offers a benefit. The PCBA functional tester can be free, including the fixture itself and the PCBA functional test. This applies if a client's order reaches the mass production stage or if the order amount exceeds $5,000.
If your PCBA project is small-batch production, we will charge the PCBA functional tester fee. Our design is free, but you'll need to cover the tester manufacturing cost for our fixture partner. Besides, the FCT fee is from $0.1 to $1 per PCBA.
The PCBA Functional Test Process
Functional testing (FCT) at PCBONLINE happens post-assembly. It occurs before the thermal aging test. Its main goal is to mimic working conditions. This verifies PCBA functionality. It ensures correct operation before distribution. A PCBA functional tester helps identify issues, such as open circuits, defective components, and solder shorts, and ensures the PCBA functions as expected. It guarantees high assembly quality.
At PCBONLINE, our test engineers use LabVIEW for test programming. A test technician connects the PCBA to the functional tester. The program is then opened, and the PCBA is powered on. When the technician operates the tester, signals are taken from the PCBA chips. The test points are routed, and parameters like voltage values and signals are loaded onto an oscilloscope.
The oscilloscope connects to a computer. It displays "OK" for a good PCBA. It shows "NG" (not good) for issues. This verifies signal integrity. Proper voltage flow is checked. All test data is recorded.
If "OK," the assembly moves to programming or thermal aging. If "NG," our engineers debug the PCBA. Testing then restarts. Tested PCBAs are sorted into a tray.
Importance of FCT in PCBA Testing
A PCBA functional tester prevents significant problems and guarantees product functionality. Errors after delivery are difficult to troubleshoot. We provide the FCT to save money and effort for our clients, as they avoid buying test equipment and hiring external test companies.
The FCT monitors responses at specific points and prevents malfunctions. This is vital for customers unable to troubleshoot. PCBONLINE advises FCT for PCBs with a total area larger than 3 square meters.
Partner with PCBONLINE for PCBA Manufacturing
PCBONLINE handles the entire PCB assembly process, from PCB fabrication, component procurement, PCB assembly, to box-build assembly if you need electronics manufacturing, including the PCBA functional test, partner with PCBONLINE.
Founded in 2005, PCBONLINE has two advanced PCB manufacturing bases in Jiangsu and Jiangxi Provinces, one turnkey PCB assembly factory in Shenzhen for PCBA and box builds. We also have an R&D team.
When your PCBA project enters mass production, we refund the fees of prototypes, provide free PCBA functional testers, and offer free PCBA functional testing.
We provide one-on-one free and professional DFM before and during prototyping/sampling, to ensure the manufacturability and project success.
Each SMT assembly line at PCBONLINE is equipped with three advanced pick-and-place machines, supporting up to 376 SMD placements per PCB, enabling us to surface mount high-density and fine-pitch PCBs.
Powerful PCBA manufacturing capabilities, including 3D SPI, 3D pre- and post-reflow AOI, X-ray inspection, first-article inspection, and selective soldering.
PCBONLINE provides PCBs, PCBAs, and box builds as a source factory manufacturer under one roof, from prototypes to bulk production, saving costs and time for you.
High-quality PCBA manufacturing certified with ISO 9001:2015, ISO 14001:2015, IATF 16949:2016, RoHS, REACH, UL, and IPC-A-610 Class 2/3.
PCBONLINE has rich experience in reflow/wave oven temperature control and offers improvement suggestions for your design, if any optimization is needed.
Whether you need PCBA prototypes or mass PCBA production for communications, consumers, automotive, medical, or industrial applications, we have the equipment, experience, and capabilities to deliver superior results for you at one stop. To get a quote for PCB and PCBA manufacturing, email us at info@pcbonline.com.
Conclusion
A PCBA functional tester is essential for ensuring device functionality and quality. PCBONLINE provides one-stop electronics manufacturing, including the PCBA functional tester and FCT. To ensure the manufacturing success of your PCBA project, partner with the turnkey PCBA manufacturer PCBONLINE.
PCB assembly at PCBONLINE.pdf
