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What Is Automatic Optical Inspection?

The demand for PCBs is growing at a rapid pace in different domains.

Over the years, consumers have been more inclined towards

PCB-integrated smart devices and electronics.

It means that PCBs are the fundamental blocks of electronics and devices.

There should be no error in the configuration of PCBs at all. It is because if

a PCB is not performing properly, it will hamper the device’s performance

as well.

Therefore, it is important that manufacturers pass their PCBs through

extreme quality check methods. It will rule out errors and defects in these

PCBs to ensure fine performance.

The complex nature of PCBs is inevitable for futuristic devices, but it

increases risks as well. Today, PCBs are at their finest, and the quality

control methods for them need to be accurate at the same time.

Speaking of which, there is not just one PCB inspection method. You can

select from multiple techniques as per your requirements and PCB

variant.

Now, we are going to take an insightful look at the importance of PCB

inspection and quality control.

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Table of Contents

Why Do PCBs Need Automatic optical inspection?

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When you design PCBs, it is important to check the final product. It makes

sure that everything is in place. Defective PCBs can lead to irreversible

damage to the devices in the future.

The PCB inspection methods detect the problems so that you can fix them

in time. Sometimes issues with PCBs are not visible, and you might

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overlook them. Now if these issues show up in the future, it will

complicate the PCB’s performance.

When you pass your PCBs through strict quality control methods, you can

point out hidden and unseen defects easily. Faulty PCBs are a big threat to

the manufacturer’s reputation, and this is how.

If a manufacturer does not make sure that its PCBs are ready for use, it

can disappoint its clients. If you need to make your customers happy with

your PCBs, never compromise on their quality.

Defective PCBs can cause electrical glitches and current leaks and can also

leave bare wires that can give shocks to the users. A faulty PCB integrated

into an electronic device can even lead to fatal consequences for the

users.

Now, you know why inspecting PCBs before handing them over to your

customers is significant to ensure consumer security and longevity of

electronics.

Inspection Methods for Printed Circuit Boards

You can define PCB inspection as a method to detect possible faults in

PCBs, re-check the positioning of PCB parts and verify the quality of

individual components after the production process.

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There are different ways of inspecting PCBs. Some manufacturers use

high-end quality control equipment and inspection machinery for this

purpose. At the same time, others use automated testing methods for

completely inspecting PCBs for defects.

However, for small and less complex PCBs, there is no need for such

measures. Workers can easily manually inspect them for faults.

It’s time to consider manual inspection and its importance for different

PCB producers in the next section!

Manual Visual Inspection

Manual visual inspection of PCBs is a basic and simplest checking method.

Workers mostly visualize PCBs themselves or might use a magnifying glass

or a microscope for this purpose.

It mostly comes in handy when PCBs are small and not too complex. The

technicians will double-check the details of the design of PCBs for the final

product so that they can verify whether the final product matches these

details or not.

The workers can manually inspect PCBs whenever they feel to. There is no

thumb rule for this type of inspection at all. However, it is better to know

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what factors you should inspect while performing MVI. These factors

would be:

 The width of the PCBs should be accurate. The texture of their

surface needs to be appropriate as well.

 The sizes of the PCB components should be suitable, and the

electrical connectors also need to be of appropriate sizes to not

make the area congested.

 The conductive components of PCBs should be standard. Make sure

the solder is in suitable amounts. There should be no gaps left on

PCBs in terms of soldering at all.

 The surface of PCBs should be free of holes, impressions, and

ridges.

 Make sure the wiring is in place and they are in optimum condition.

 The pad plating should also be working at its finest, and to make

sure of this, there should be no extra roughness and rigidness.

 The quality of the coating should be flawless, and for this, you need

to verify its amount of flux and placement.

· Now, let’s have a look at some benefits of using MVI for PCB

manufacturers:

 It is not a complex method, and workers can perform it easily

 It is affordable and does not disturb a manufacturer’s budget at all

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 MVI does not work with complex futuristic quality control tools

 The technicians can perform MVI at different intervals of the

production process

Benefits

The only thing that you should keep in mind for executing MVI is the

eligible workers. Skillful technicians that know how to get along with MVI

come in handy. They will help in precisely detecting the problems with

PCBs without using any tools and equipment.

Drawbacks

 It does not detect hidden defects of PCBs

 It is not viable to use for complex PCBs

 There are more chances of overlooking possible defects of PCBs

due to MVI

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Automated Optical Inspection

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MVI is a simple inspection method, but it does not guarantee positive

results. There is still a margin left for human error. However, one

remarkable inspecting technique called automated optical inspection of

PCBs can save you from errors.

The process involves a video camera and lights to ensure 100% quality of

PCBs. The purpose of the lights is to emphasize PCBs to easily detect their

faults. Light from all directions helps in identifying the flaws in them.

After this, the cameras will film the PCBs and take images as well. In this

way, the technicians will match this final product with the design

requirements in the end. The process uses high-end equipment that

includes 3d and 2d cameras.

You can even use colored lights from different directions for this purpose.

AOI is the latest technique that can prove to be a great alternative to MVI

in the near future.

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Automatic Laser Test Measurement

In case the former methods were not of use to you, try Automatic later

test inspection of PCBs.

The purpose of ALT is to verify the sizes of solder joints of PCBs and their

parts. The process involves different industrial-grade lasers that help to

detect the assembly of PCB parts.

The worker will reflect the light on the components to check their

positioning and detect any faults in them. The process is useful and works

on different calculations to see if the PCB is of quality or not. You can ALT,

especially when there is a need to apply solder paste on the PCB parts

every time.

Not only this, there are other benefits of using ALT. Have a look at them

below:

 Helps with the PCB parts assembly

 Detects the viscosity

 Identifies the component cleanliness

 It also assists with the printing of solder paste when needed

 It is an insightful method and gives output data in the form of

analysis and stats

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Drawbacks

 The final data given by ALT is always correct; however, factors like

interference and shielding can change the values if not controlled

before or during the process.

What Is Via Filling?

No PCB design can work in an optimal environment without its vias. These

are an integral part of PCBs that give them different features to perform

naturally. The role of PCB vias is to transfer signals within all the layers of

PCBs precisely.

Vias in the PBs are to make sure that each layer is sending and receiving

signals without any disturbance. These vias are just small holes packed

with copper. These vias also join the layers with each other.

The copper in the vias should leave no space in order to achieve positive

results. However, the filling of copper should be controlled since

overfilling can make the PCB layers hefty. An extra copper filling will also

overweight the PCBs.

Today, small and portable PCBs are common, and the vias for these are

also small. Sometimes regulating everything in a small area becomes

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troublesome; however, a seasoned PCB manufacturer will perform this

challenging task efficiently.

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Advantages of a Via Fill PCB

The PCBs with via fillings are more promising than those without vias.

These PCBs collectively benefit your electronics in many ways. We are

going to see why via-fill PCBs are crucial.

 The components of such PCBs offer great surface mounting when

needed.

 The via-fill PCBs never stop liquids and air from escaping from the

system, which makes them more reliable than other forms of PCBs

 The PCB assembly will be free of defects making it dependable in

the long run for the users.

Copper-Filled and VS Copper-Plated Via

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The two types of vias for PCB designs are either copper-filled or copper

plated. Now, don’t get excited to know this because there are different

applications of these types. We are going to discuss the benefits of

copper-filled vias in detail for you.

 Such vias are important for boosting thermal conductivity due to

the presence of copper.

 Copper vias are also beneficial in enhancing the performance of

PCBs when it comes to handling hot temperature conditions.

 Copper can absorb large amounts of heat and leaves enough space

for other components to stay cool in the case when the

temperature exceeds

 The heat can flow from one portion to the other, which reduces the

chances of defects due to copper vias.

Benefits of Copper over Gold for a Via Fill PCB

You might be wondering, at this point, why not use gold for via-fill PCBs?

Well, it’s shocking to know that different PCB manufacturers will use epoxy

resins and gold as fillings in place of copper for such PCBs.

However, at the end of the day, you will get positive results from these

fillings. For this purpose, copper gives the best output as compared to

resins and gold.

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Below are some facts that will make you realize why using copper for

via-fill PCBs is recommendable:

 Gold has less potential for thermal conductivity and electrical

transmission than copper

 Copper enhances the longevity of PCBs for users

 Copper is much more affordable than gold which makes it a reliable

option to use via fill PCBs

 Different analysis shows that copper via fill PCBs are more reliable

 High-powered electronics and smart gadgets can hugely benefit

from copper vias instead of using gold and resins

Summary

Humans always get confused when making their choice between two

options. To save you from such frustration, we are giving you some factors

that will help you weigh down via filling options easily.

 Consider your application: Get to know about your purpose

completely. The purpose you are going to use via filling entirely

depends on the application.

 Keep in mind the price: Some via fillings, like gold fillings, are too

expensive to waste in errors, so make sure you are using an

affordable via filling for your PCBs

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 Aim to make the design as straightforward as

possible: Complicating your PCBs will not set you apart from other

manufacturers; instead, always keep the designs basic which will

help in ruling out errors in them as well.

The End Note

Via Fill PCBs have a bright future because of their vast applications for

users. In this post, you have learned about the role, significance, and

benefits of using copper via fill PCBs for your future projects.

However, in case you have any queries in mind, consult a seasoned PCB

producer near you. They will clear your mind and also can assist you with

cost-efficient via-fill options for your PCBs.

Related Posts:

1. AOI Machine: A Comprehensive Overview of Automatic Optical

Inspection Systems

2. What is the Importance of Optical PCB?

3. What are the Criteria for PCB Inspection?

4. What is SMT inspection?

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