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Manual Through Hole Assembly

Manual Through Hole Assembly
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At STHL Technology's production facilities, Manual Through Hole Assembly is not synonymous with "outdated processes," but rather reflects a commitment to quality and adaptability to specialized requirements.

When dealing with components that cannot be fully automated — such as irregularly shaped high-power devices, custom interfaces, or sensitive sensors — our team of experienced technicians performs precise insertion and soldering at anti-static workstations, using precision jigs, magnifiers, and microscopes to ensure every solder joint meets IPC A 610 high reliability standards.

Leveraging over 20 years of PCBA manufacturing experience, a comprehensive quality management system, and flexible production line configurations, STHL can seamlessly switch between high-volume automated production and high precision manual processes, providing customers with optimal through hole assembly solutions.
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Description
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What is Manual Through Hole Assembly?

 

Through-hole assembly involves inserting component leads through pre-drilled holes in a PCB and soldering them on the opposite side. Compared to SMT, through-hole connections offer greater mechanical strength and heat resistance, making them ideal for high stress, high temperature environments.
Manual Through Hole Assembly, in which skilled technicians carry out insertion and soldering by hand, is particularly suited for:

  • Components with unusual shapes or non standard packages
  • Heat sensitive components
  • Small batches, prototypes, or mixed model production
  • Components in SMT+THT mixed boards that cannot be inserted automatically
dip tht

 

Core Process

 

1. Workstation Preparation

  • Verify component model, polarity, and pad position against the BOM and circuit schematic.
  • Maintain full anti static protection at the workstation to safeguard sensitive components.

2. Precision Insertion

  • Use manual jigs to ensure pin verticality and consistent insertion depth.
  • Apply reinforcement for high power or mechanically stressed components.

3. Soldering Process

  • Options include wave soldering, selective wave soldering, or manual soldering with a soldering iron.
  • Use localized soldering for heat sensitive components to prevent thermal damage.

4. Inspection and Correction

  • AOI (Automated Optical Inspection) or manual visual inspection.
  • Focus on solder joint shape, wetting quality, and component placement.
  • First article approval and spot check procedures ensure batch wide consistency.
aoi

 

Common Through-Hole Component Types

 

  • High‑power resistors, inductors, transformers
  • Electrolytic capacitors, audio transformers, and other components with strict solder joint requirements
  • Mechanical components such as relays, switches, and long pin headers
  • Special sensors and custom interface modules

 

Advantages of Manual Through Hole Assembly

High Adaptability
Assemble special structure components without design changes.
Low Fixture Costs
Ideal for R&D stages and market validation.
Controllable Quality Feedback
Design issues can be identified and addressed during assembly.
High Reliability
Skilled manual workmanship can fully meet the quality standards of automated soldering.

 

Application Examples

 

  • Industrial Control Boards: Motor control units with high power relays.
  • Automotive Electronics: Control modules meeting automotive grade temperature and vibration standards.
  • Medical Equipment: Inspection modules with extremely high demands for solder joint consistency and reliability.
  • Professional Audio Equipment: High quality soldering of large capacitors and transformers.
pcba

 

Summary and Invitation for Collaboration

 

At STHL, we regard Manual Through Hole Assembly as a critical link in the high reliability manufacturing chain. Whether for small batch prototypes, specialized process adaptation, or soldering critical components in mixed production, we deliver flexible, high quality through hole assembly solutions.

 

Send your Gerber files and requirements to: info@pcba-china.com - Let us provide a high standard Manual Through Hole Assembly that keeps your product ahead in both performance and delivery.

 

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