The Step-by-Step Aluminum PCB assembly process

Aluminum PCBA assembly

Have you witnessed the dynamic evolutions in electronics, specifically PCB assembly? Engineers often incorporate aluminum in current electronics due to its high-temperature withstanding capability and reliability. In addition, its lightweight increases the mobility of PCBs and electronic devices. However, like any other PCB, the aluminum PCB assembly involves a series of progressive iterations. Additionally, current assembly involves automatic processes and developed technology. Consequently, manufacturers can assemble the Aluminum PCB faster than traditional manual methods. The following information outlines the iterations involved in aluminum PCB assembly.

Component checking

Aluminum PCB assembly process

We first purchase the materials and components following the PCB specifications and the Buyer’s Bill of Materials (BOM). In addition, if some are not readily available, we must substitute them with equivalent ones with the buyer’s consent. Furthermore, Design for Manufacturability (DFM) is also significant. To prevent any delays in the PCB assembly process, professionals double-check each document. Finding the issues is preferable because doing so immediately identifies any faults or problems.

Fabricating PCB

The creation of the PCB is the following stage. First, we must fabricate the Aluminum PCBs following the buyer’s specifications. In this stage, we start with an empty, bare board on which we will mount the components. Note that we must initially ensure that our bare board has the intended PCB dimensions in length and width.

Solder paste application

Next, using a stencil, we apply solder paste to the specific PCB locations. In this stage, we apply the paste to the area where we finally intend to have our components. With the current technology, we can achieve this phase automatically using a solder printing machine. To apply the paste to the PCB, we first place enough of the paste inside the apparatus. We can liken this to a stencil-using t-shirt printing machine for better understanding. The main difference in the aluminum PCB assembly is employing solder paste rather than paint.

Additionally, to apply the paste to the PCB, set the stencil over the board and roll it over. Consequently, the paste flows into the board’s holes and pads. The usage of the metallic stencil is more accurate and aids in applying the solder just to the necessary regions.

Component picking and placement

It’s time to attach the components to the board after we have applied the solder paste. Although we can do it manually, we currently employ machines for speed and more accuracy. Therefore, we first feed the component reels into the machine. Furthermore, we position these reels differently depending on the situation. Then, the machine selects the components before setting them where they belong later. Consequently, we call this procedure Pick and Place. It’s an automated process in which the machine receives the data from the files and uses it to carry out the necessary tasks.

Reflow soldering in aluminum PCB assembly

Aluminum PCB Manufacturing

Soldering the components begins after correctly positioning them to their respective points. Since we have already used the solder paste, we only need to ensure that the components have a proper electric connection, which we melt once more. We now put the PCB through a reflow oven to melt it a second time. It moves through the oven while mounted on a conveyor belt. Reflow soldering is the term for this technique. The solder, which secures the parts and completes the electrical connections, must melt for the oven to function correctly. However, the board is quite hot inside the oven, so we must allow it to cool before removing it. The components are back where they started after reflow soldering. The Aluminum board needs to undergo testing to guarantee quality before it is ready for usage.


Inspection is a crucial stage in Aluminum PCB assembly as it finds mistakes and defects. Therefore, we must perform this procedure on every PCB to ensure it meets standards. For example, the constructed PCB may have a short circuit, improper component arrangement, or any other issue. Inspection is thus a pivotal stage. In addition, both manual and mechanical inspection methods are available. Manufacturers typically manually inspect the assembled PCB to look for any apparent flaws before using other methods like X-ray and AOI. Although manual inspections are unreliable, the manufacturers still employ them to find PCB flaws.

X-ray Inspection

X-ray examination is a robust technique that aids in identifying multilayer PCB flaws. Everything becomes evident when the light penetrates the layers. Moreover, we prefer this sophisticated technique for challenging PCB designs. On the other hand, it may be quick and easy to discover PCB issues. This is because the defect and its underlying cause are simple to find during an X-ray examination. Equally important is that since the connections are underneath the components, it may be difficult to see any defects with the unaided eye or during AOI testing. We, therefore, employ X-ray inspection in these situations.

Consequently, the inspection assures us of the high quality and reliability of the PCB. In this manner, the rays can leave the components and come from the PCB. They can show where the component’s joints and electrical connections locations. Through reflection, the beams produce an image that we can examine via image processing. The soldering joints are hence visible in the photograph that the machine generates.


We now perform the automatic optical inspection (AOI). Despite being quicker and easier than X-ray inspection, this technique is only partially useful because it cannot view the hidden connections beneath the components. Instead, it uses cameras to examine the PCB from various perspectives. However, we can use it to inspect a big batch of ready PCBs quickly.

Final testing

Having checked for any faults, we now conduct a final functional test. In this case, we examine our PCB to see if it produces the required outcomes. We can apply different techniques to test it. We review our Aluminum PCB to determine whether it is yielding the results we expected or not. If the outcomes match our expectations, we now continue to product delivery to the client. However, if the results differ from our final expectations, we repeat the whole assembly procedure since repairing the PCB is tricky.


PCB manufacturing involves designing, fabricating, and interfacing several electronic components to achieve a functional combined circuit. Furthermore, designing the PCB is easier compared to the actual assembly process. The above details explain the steps to follow during the assembly of Aluminum PCBs. However, to achieve a ready PCB with the above procedure, you must acquire the different machinery and equipment for each step. It is pivotal to ensure that you test its functionality after manufacturing the Aluminum PCB through the above iterations. Consequently, you can term your Aluminum PCB assembly process successful.

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