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We are now building 48 inch (1200mm) SMT assemblies.

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#75381

We are now building 48 inch (1200mm) SMT assemblies. | 23 February, 2016

We finally got our long board line up and running. As a Contract Manufacturer, of course, we are at the mercy of our customers. I'm wondering if anyone else that is producing these large assemblies might have any advice on handling or any other pitfalls we might encounter along the way?

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#75382

We are now building 48 inch (1200mm) SMT assemblies. | 23 February, 2016

Good to hear! Never dealt with an assembly that large. 24" is the longest we've built. One issue we encountered was bowing due to the vacuum seal being too tight. Bowing caused transfer issues between conveyors and equipment.

-TSS

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#75612

We are now building 48 inch (1200mm) SMT assemblies. | 28 April, 2016

That is a large board, maybe some supports to help with bow. http://www.nozzleforled.info/ezload-pcb-support-modules.html

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#75614

We are now building 48 inch (1200mm) SMT assemblies. | 29 April, 2016

With an assembly that large Scrap is now a huge thing. I wouldn't let any transport happen off of a cart 1 bump or ding into an object could ruin your day. Does Bliss make a cart big enough? How would you even wash it? The mind boggles. Good luck!

On a side note, I would love to read a white paper on your process if/when you ever nail it down.

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#75615

We are now building 48 inch (1200mm) SMT assemblies. | 29 April, 2016

What info on the process would you like to know?

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#75647

We are now building 48 inch (1200mm) SMT assemblies. | 3 May, 2016

Mainly handling issues. I had some heavy boards (solid copper core) that cost some money, like $1200 ea. As they were oddly heavy that they would catch operators off guard, and scrap was a serious issue.

Another thing that i dealt with when processing the heavy boards was getting them up to temp before soldering. We had to put them into an oven to preheat them before they could be placed into the wave solder machine. I am curious if you have a similar problem.

Also shipping, do you have to put them on a pallet and send them by truck?

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#75648

We are now building 48 inch (1200mm) SMT assemblies. | 3 May, 2016

These were strictly SMT boards, so no preheat was required. It was interesting watching the output from the thermocouples since the board was essentially in 3 oven zones at once. I had over 110C delta end to end.

The boards were 48" long, but only an inch or so wide, in an array of 5.

Shipping I used a long box, like you'd ship documents in. I had toyed with the idea of using PVC pipe, but haven't gone down that road yet.

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#75654

We are now building 48 inch (1200mm) SMT assemblies. | 4 May, 2016

I heard 48" and thought about a 48x48 board. I never thought about it being slender. PVC would be heavy (costing more to ship), there are cardboard tubes that you can get cut that long for cheaper.

Sounds like you have your process dialed in.

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#75655

We are now building 48 inch (1200mm) SMT assemblies. | 4 May, 2016

I guess I didn't mention, the PVC was because the tubes had a lead time and minimum quantity that didn't work for the project. So we needed to find something in a day. I ended up finding a rectangular box that was 52" long. The first run was a small number of boards, so a few of those boxes and bubble wrap worked ok. In the long run, the custom tubes will be the solution.

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#75756

We are now building 48 inch (1200mm) SMT assemblies. | 19 May, 2016

Curiosity is killing me... What printer and pick n place machines are you using?

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#75759

We are now building 48 inch (1200mm) SMT assemblies. | 20 May, 2016

A modified Samsung SM482 and a heavily modified tabletop printer.

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#75834

We are now building 48 inch (1200mm) SMT assemblies. | 3 June, 2016

If it will not violate your company rules, or generally get you in trouble. Can you post up a few pictures, or possibly a video?

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#75836

We are now building 48 inch (1200mm) SMT assemblies. | 3 June, 2016

https://youtu.be/9wDZbI-H9RM Same machine. Board shift is at about 2:30.

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#75853

We are now building 48 inch (1200mm) SMT assemblies. | 7 June, 2016

Thank you! Very nicely done.

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