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Through-Hole PCB Assembly

PCBSAIL provides professional Through-Hole PCB Assembly services for electronic products that require superior mechanical strength, high power handling, and long-term reliability.

Our THT (Through-Hole Technology) assembly solutions are widely used in industry, where circuits must withstand vibration, thermal stress, high voltage, and harsh environmental conditions.

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What Is Through-Hole PCB Assembly

What Is Through-Hole PCB Assembly?

Through-hole PCB assembly is a process where electronic components are inserted into pre-drilled holes on a PCB and soldered onto pads on the opposite side.

Through-hole PCB assembly can establish strong mechanical anchoring and highly reliable electrical connections.

Unlike Surface Mount Technology, where components are mounted directly on the board surface, through-hole assembly can:

  • Anchors Component Leads Through The PCB
  • Creates Stronger Mechanical Bonds
  • Improves Resistance To Stress And Vibration

Through-hole PCB assembly is widely used in industry, such as automotive electronics, industrial control systems, aerospace, and power electronics.

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Our Through-Hole PCB Assembly Capabilities

We deliver comprehensive through-hole PCB assembly capabilities designed to meet the requirements of high-reliability, high-power, and mechanically demanding applications.

Flex PCB Manufacturring Process

Component Compatibility

We support a broad spectrum of through-hole electronic components, ensuring flexibility across various product designs and industries:

  • Axial And Radial Lead Components
  • Large And Heavy Components
  • High-Current Connectors And Terminals
  • Press-Fit Components For Solder-Free Applications

Flex PCB Manufacturring Process

Advanced Soldering

We utilize multiple soldering to match different design and production requirements:

  • Wave Soldering Optimized: For high-volume through-hole assembly
  • Selective Soldering: High precision with positional accuracy of approximately ±0.5 mm
  • Manual Soldering
  • Nitrogen-Assisted Soldering

Flex PCB Manufacturring Process

Press-Fit Assembly

For applications requiring solder-free connections, we offer press-fit technology:

  • Gas-tight, highly reliable electrical connections
  • Insertion force range: 10–50 N per pin
  • Validated per IPC-9797 standards

Flex PCB Manufacturring Process

Structural Capability

We support a wide range of PCB constructions:

  • Single-sided PCBs
  • Double-sided PCBs
  • Multilayer PCBs (up to 64 layers)

Flex PCB Manufacturring Process

Materials

Our material are tailored to meet electrical, thermal, and environmental demands:

  • FR4 and high-Tg FR4
  • Halogen-free laminates
  • Rogers high-frequency materials

Flex PCB Manufacturring Process

Copper Thickness

We support copper thicknesses up to 1000 μm, enabling:

  • High current-carrying capacity
  • Enhanced heat dissipation
  • Stronger mechanical bonding between components and PCB

Flex PCB Manufacturring Process

Reliability Process Control

Our manufacturing process incorporates strict process control and monitoring:

  • Thermal profiling with ΔT controlled within ±5°C
  • Flux density verification for consistent solder quality
  • Lead forming with controlled bend radius to prevent component stress
  • Fixture-level SPC (Statistical Process Control) for repeatability

Flex PCB Manufacturring Process

Production

Our through-hole assembly lines are designed for scalability:

  • Prototype production (1–100 units)
  • Low-volume manufacturing (100–10,000 units)
  • High-volume production (10,000+ units)

Through-Hole PCB Assembly Feature

Our through-hole PCB assembly services can deliver exceptional mechanical strength, electrical reliability, and long-term performance in demanding operating environments.

Through-Hole PCB Assembly Feature

Through-hole assembly provides superior mechanical anchoring by inserting component leads through plated holes and soldering them on the opposite side of the PCB.

  • Strong resistance to vibration and mechanical shock
  • Secure retention of heavy and large components
  • Reduced risk of pad lifting or component detachment

The through-hole structure forms robust electrical connections with low resistance and high stability.

  • Full barrel soldering ensures consistent conductivity
  • Reliable performance under high current and voltage conditions
  • Reduced risk of intermittent connections or signal loss

Through-hole PCB assemblies are designed for high-power applications:

  • Supports thick copper up to 1000 μm
  • Efficient heat dissipation through plated through holes
  • Withstands thermal cycling and temperature fluctuations

Through-hole assemblies are designed to perform reliably under harsh conditions:

  • Resistant to humidity and corrosion
  • Maintains performance under vibration and shock
  • Handles extreme temperature environments
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Through-Hole PCB Assembly Process

We follow a structured and tightly controlled through-hole PCB assembly process to ensure high mechanical strength, electrical reliability, and repeatable quality.

Flex PCB Manufacturring Process

Design Review

Before production begins, our engineering team will review a comprehensive design:

  • Hole Size And Tolerance Verification
  • Pad And Annular Ring Design Assessment
  • Component Layout Optimization For Insertion And Soldering
  • Thermal Relief And Copper Balance Analysis
  • Mixed-Technology (SMT + THT) Process Planning

Flex PCB Manufacturring Process

Component Sourcing

All components are sourced from authorized and traceable suppliers to guarantee authenticity and consistency.

  • Incoming Quality Control Inspection
  • Verification Of Part Numbers, Packaging, And Specifications
  • Moisture Sensitivity Level Control Where Applicable

Flex PCB Manufacturring Process

PCB Fabrication

Bare PCBs are manufactured and prepared for assembly:

  • CNC Drilling Of Through Holes
  • Copper Plating Of Vias And Holes (Typically 20–25 ΜM)
  • Surface Finish Application
  • Solder Mask And Silkscreen Printing

Flex PCB Manufacturring Process

SMT Pre-Assembly

For hybrid designs, SMT components are assembled first:

  • Solder Paste Printing
  • Pick-And-Place Component Mounting
  • Reflow Soldering With Controlled Thermal Profiles

Flex PCB Manufacturring Process

Component Lead Preparation

Before insertion, component leads are prepared:

  • Lead Cutting And Forming To Match PCB Hole Spacing
  • Controlled Bend Radius To Avoid Component Stress
  • Coplanarity Checks For Proper Alignment

Flex PCB Manufacturring Process

Component Insertion

Components are inserted into pre-drilled holes using:

  • Manual Insertion For Prototypes And Complex Layouts
  • Automated Insertion For High-Volume Production
  • Odd-Form Placement Systems For Irregular Components

Flex PCB Manufacturring Process

Soldering Process

We use multiple soldering to match different production requirements.

  • Wave Soldering
  • Selective Soldering
  • Manual Soldering

Flex PCB Manufacturring Process

Flux Residue Removal

After soldering, assemblies undergo cleaning:

  • Removal Of Flux Residues And Contaminants
  • Ionic Contamination Control
  • Surface Cleanliness Verification

Flex PCB Manufacturring Process

Quality Control

We will use multi-stage inspection to detect defects early:

  • AOI
  • X-ray Inspection
  • Cross-Section Analysis:

Flex PCB Manufacturring Process

Electrical Testing

To ensure functional performance, we conduct:

  • In-Circuit Testing
  • Functional Circuit Testing
  • High-Voltage And Signal Integrity Testing
  • Boundary-Scan Testing

Flex PCB Manufacturring Process

Packaging

Finished products are securely packaged:

  • Anti-Static (ESD-Safe) Packaging
  • Moisture Barrier Bags (If Required)
  • Shock-Resistant Shipping Materials

Wave Soldering Machine
Universal SMT Machine
SPI
Speed SMT Machine
Sample Tester
Reflow Oven
Laser Stencil Mach
KIC Oven Profiling System
Fully Automated PCB Depaneling Equipment
Automatic Printing Machine
AOI Machine

Industries We Have Previously Served

Our through-hole PCB assembly solution are widely used in industries that demand high reliability, mechanical durability, and long operational lifecycles.

PCB Manufacturer Automotive Electronics

Automotive Electronics

We support automotive manufacturers and Tier 1 suppliers with robust PCB assemblies designed for harsh operating environments.

  • Engine Control Units (Ecus)
  • Battery Management Systems (BMS)
  • Power Distribution Modules
  • On-Board Chargers And Inverters

PCB Manufacturer Industrial Automation

Industrial Automation

Industrial environments require durable electronics capable of continuous operation under mechanical and electrical stress.

  • PLC
  • Motor Drives And Servo Controllers
  • Industrial Power Supplies
  • Human-Machine Interface (HMI) Systems

Aerospace

Aerospace

We provide high-reliability assemblies for aerospace and defense systems.

  • Avionics Systems
  • Radar And Communication Equipment
  • Navigation And Control Modules

PCB Manufacturer Medical Devices

Medical Electronics

Medical devices require precision, stability, and long-term reliability under strict regulatory standards.

  • Diagnostic Equipment
  • Patient Monitoring Systems
  • Imaging Systems
  • Laboratory Instruments

PCB Manufacturer Consumer Electronics

Consumer Electronics

For consumer products requiring durability and longevity, through-hole assembly offers added reliability.

  • Audio Equipment
  • Power Adapters
  • Home Appliances
  • Gaming And Entertainment Systems

PCB Manufacturer Telecommunications

Telecommunication

We support telecom equipment manufacturers with reliable PCB assemblies for network infrastructure.

  • Base Stations
  • Signal Amplifiers
  • Network Switching Equipment
  • RF Power Modules

Power Electronics

Energy Systems

Through-hole PCB assembly is ideal for high-power applications due to its strong mechanical and electrical properties.

  • Switching Power Supplies
  • Solar Inverters
  • Energy Storage Systems
  • Power Distribution Units

Fast Quotation

Our professional sales and engineering teams provide fast PCB quotes and technical support. Simply send us your Gerber files, BOM, and assembly drawings, and we will respond promptly with a competitive solution.

  • Gushu Tangxi Second Industrial Zone, Shenzhen
  • +86 755 2335 0814
  • +86 135 1078 8094
  • sales@pcbasail.com

FAQ About Through-Hole PCB Assembly

1. What Is Through-Hole PCB Assembly?

Through-hole PCB assembly (THT) is a process where electronic components are inserted into drilled holes on a printed circuit board and soldered on the opposite side. It creates strong mechanical and electrical connections, making it ideal for high-reliability applications.

  • Through-hole (THT): Components are inserted into holes, offering strong mechanical bonding and durability.
  • Surface Mount Technology (SMT): Components are mounted directly onto the PCB surface, enabling smaller size and higher density.

THT is preferred for high-power and mechanically demanding applications, while SMT is used for compact, high-speed designs.

You should choose through-hole assembly when your design requires:

  • High Mechanical Strength
  • Support For Large Or Heavy Components
  • High Current Or High Voltage Handling
  • Resistance To Vibration And Thermal Stress

Yes. It is called mixed-technology assembly. SMT components are typically placed first, followed by through-hole insertion and soldering. This approach combines compact design with mechanical strength.

Industry standards include:

  • IPC-A-610 Class 2 (general electronics)
  • IPC-A-610 Class 3 (high-reliability electronics)
  • ISO 9001 quality management
  • IATF 16949 for automotive applications
  • RoHS compliance for environmental safety

Barrel fill refers to how completely the plated hole is filled with solder.

  • Class 2 requirement: typically >75%
  • Class 3 requirement: typically >90%

Proper barrel fill ensures strong electrical conductivity and mechanical stability.

Lead times depend on complexity and volume:

  • Prototype: 4–7 days
  • Small batch: 7–15 days
  • Mass production: 15–25 days

Fast turnaround options are available for urgent projects.

While SMT is generally preferred for high-frequency PCB, through-hole assembly can still be used for:

  • Power Sections
  • Connectors
  • Mechanical Reinforcement

Hybrid designs often combine SMT for signal paths and THT for structural components.

We support copper thickness up to 1000 μm, enabling high current handling and improved heat dissipation.

Yes. We offer full Turnkey PCB Assembly solutions including:

  • PCB fabrication
  • Component sourcing
  • Assembly
  • Testing
  • Box build integration

You can request a quote by providing:

  • Gerber files
  • Bill of Materials (BOM)
  • Assembly drawings
  • Quantity requirements

Our team typically responds within 8 working hours for PCB quotes and 1–2 days for full PCBA quotations.