High Volume PCB Assembly
for Scalable, Precision Electronics Production
WellPCB delivers advanced high-volume PCB assembly services engineered to meet demanding performance requirements across industries. Our proven assembly solutions maintain superior quality and reliability even under extreme operating conditions and high-stress applications.
- Complete turnkey assembly services with certified quality control and full traceability
- Automated high-volume production with comprehensive design optimization support
- Advanced assembly capabilities for complex, high-reliability electronics
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ISO9001 ISO13485
ISO14001
IATF
16949
IPC-A-610H International
Certification
Fully Automated
AOI Inspection
Scalable PCB Assembly for Mass Production Across Industries
WellPCB offers high volume PCB assembly for production runs ranging from 1,000 to over 100,000 PCB assemblies per order. We support SMT, THT, and mixed-technology builds using high-speed pick-and-place machines with ±30 µm accuracy and up to 60,000 CPH output per line. Every board undergoes inline SPI, AOI, and X-ray inspection to meet Class 2 or Class 3 specifications.
Our assembly processes are designed to handle demanding applications, including automotive and industrial electronics that must maintain electrical and mechanical integrity across -40°C to +125°C, resist vibration up to 10G, and withstand continuous thermal cycling. We utilize SMT and THT assembly using nitrogen reflow ovens, selective wave solder, and comprehensive SPI/AOI/X-ray testing protocols.
We assemble printed circuit boards on FR4, High Tg FR4, aluminum core, and advanced laminates for high-reliability electronics. Supported PCB sizes range from 50 mm × 50 mm up to 610 mm × 508 mm, with thicknesses between 0.5 mm and 4.5 mm. Minimum BGA pad spacing is 0.35 mm, and QFP pitch down to 0.15 mm.
Volume PCB assembly services include full DFM/DFA analysis, stencil or jet solder paste deposition, nitrogen-assisted reflow, and wave soldering. Our BOM validation process flags incompatible or obsolete parts before production. We build prototype and high-volume PCBs with full component traceability and documentation formatted to IPC-2581, maintaining IPC-A-610H Class 2/3 quality control standards with in-line process validation for every batch.
Whether you need small-batch pilot production or fully scaled high-volume PCB manufacturing and assembly, we offer a one-stop PCB solution with strict process control, stable turnaround, and Class 3 test protocols on request. The PCB assembly process follows a fixed sequence: solder paste application, pick-and-place, thermal processing, optical inspection, and packaging.
Our High Volume PCB Assembly Capabilities
We support high-volume PCB assembly across a wide range of industries by combining advanced pick-and-place systems, nitrogen reflow ovens, wave soldering, and full in-line testing. Our facilities are optimized for high-throughput, high-reliability production, with IPC-A-610 Class 2/3 workmanship, end-to-end traceability, and full BOM validation built into the assembly process.
SMT lines handle 0201 passives, 0.2 mm pitch BGAs, and fine-pitch QFPs. They use Siemens and Yamaha equipment to achieve ±30 µm accuracy with up to 60,000 CPH throughput
THT is performed using nitrogen-assisted wave soldering or selective soldering for hybrid assemblies.
| Parameter | Specification |
|---|---|
| Placement Speed | Up to 60,000 chips per hour |
| Assembly Types | SMT, Through-hole, Single Side/ Double Side, and Mixed Technology |
| SMT Line | 5 Siemens + 8 Yamaha |
| PCB Size | 50 mm×50 mm ～610 mm×508 mm |
| PCB Thickness | 0.5 mm～4.5 mm |
| SMT Accuracy | ±30 µm (3σ, CPK ≥ 1) |
| Minimum BGA Pad Spacing | 0.35 mm |
| Minimum QFP Pitch | 0.15 mm |
| Component Size Support | 0201 passives to large BGA/LGA |
| Reliability Test | Flying Probe Test/Fixture test, Impedance Test, Solderability Test, Thermal Shock Test, Hole Resistance Test, and Micro Metallographic Section Analysis, etc. |
| Standards | ISO14001:2015, ISO9001:2015, ISO 13485:2016, IATF16949: 2016, IPC-A-610H |
We apply solder paste using 100 to 150 µm stainless-steel laser-cut stencils or software-controlled jet dispensers.
Jet printing eliminates stencil changes between PCB revisions, while stencil printing allows rapid coverage for uniform pad geometries on large volume PCB assemblies.
All SMT assembly uses numerically controlled machines with vision alignment for real-time correction.
We support component delivery via reels, trays, tubes, or cut-tape with inline feeders, all handled under moisture and ESD protocols, enabling continuous, unattended operation during high-volume PCB assembly service.
Reflow soldering profiles are tuned to prevent voids, with consistent ramp rates and controlled soak zones to protect fine-pitch components.
This occurs in 8 to 10 zone ovens with programmable thermal profiles, stable ramp-to-soak transitions, and nitrogen reflow atmospheres.
THT and mixed assemblies are processed using dual-wave soldering systems with adjustable dwell, conveyor pitch, and flux density.
We maintain active supply pipelines across Digi-Key, Mouser, Avnet, and Arrow to reduce sourcing delays in high-volume PCBA production.
All BOMs undergo validation to identify mismatches, pinout errors, and obsolete parts before pcba production begins.
In-line AOI and SPI detect solder paste height, tombstoning, and component offset within 10 µm tolerances.
X-ray inspection checks hidden joints beneath BGAs and LGAs. ICT and FCT are supported using flying probe or bed-of-nails test fixtures with programmable test scripts.
All volume PCBA builds are performed in ISO 8 cleanroom environments with ESD protection, compressed air filtration, and lead-free soldering compliance.
Each step, from stencil printing to packaging, is logged in our production management system using IPC-2581 data formats.
Why Choose WellPCB for Your High Volume PCB Assembly?
One-Stop PCB Manufacturing and Assembly
Mass Production Capability
Global Sourcing and BOM Flexibility
Class 2/3 Quality Control Systems
WellPCB assemblies meet IPC-A-610 Class 2 or Class 3 depending on project needs.
All work is performed under ISO 9001 and ISO 14001 certified systems with AOI, SPI, X-ray, and electrical testing options available.
Fast Turnaround for High Volume Orders
Standard lead times range from 5 to 25+ business days, depending on part complexity and volume.
Expedited options are available for SMT PCB assembly projects with stable designs and pre-approved BOMs.
DFM Checks and Engineering Support
What is High Volume PCB Assembly?
High volume PCB assembly is the automated production of 1,000 to 100,000+ printed circuit board assemblies using SMT, THT, or mixed technology. It begins with DFM and DFA validation, followed by stencil or jet solder paste application, precision pick-and-place, and nitrogen-assisted reflow or wave soldering.
These assemblies are built in continuous runs using barcode-based tracking and IPC-2581 digital documentation. AOI, SPI, and X-ray testing are integrated to maintain Class 2 or Class 3 compliance across large batches. This method reduces per-unit cost, shortens turnaround time, and supports fine-pitch components in consumer, automotive, industrial, and telecom applications.
Our Quality Control and Industry Standards
We maintain strict process control across every high volume PCB assembly using certified quality systems, real-time inspection, and serialized documentation. Our factories are designed to meet the IPC, ISO, and environmental standards that govern soldering, testing, and traceability in large-scale electronics production.
IPC-A-610 Class 2/3 and J-STD-001 Workmanship
ISO 9001 and ISO 14001 Certified Facilities
WellPCB operates under ISO 9001 for quality management and ISO 14001 for environmental compliance.
All assembly work is performed in controlled environments with document-based process control.
Work instructions, part traceability, and inspection records are maintained per batch, ensuring consistency across all production runs.
AOI, SPI, and X-Ray Process Inspection
Automated Optical Inspection systems detect tombstoning, skew, and insufficient solder volume at <10 µm resolution.
Solder Paste Inspection verifies stencil and jet-deposited paste with height and coverage thresholds.
For BGA, LGA, and QFN packages, X-ray systems analyze voids, solder fillet quality, and joint collapse symmetry.
In-Circuit and Functional Testing Capabilities
ISO 8 Cleanroom and ESD Safe Environment
IPC-2581 Traceability and Documentation
Industries We Serve With
High Volume PCB Assembly
We manufacture high-volume PCB assemblies for industries that demand electrical reliability, thermal stability, and consistent production output. Our capabilities support both high-speed signal processing and ruggedized electronics for complex environments, with Class 2/3 compliance, full traceability, and component-level control across all sectors.
Consumer Electronics
Automotive Systems
Medical Devices
Aerospace and Defense
Industrial Automation
Telecommunications
How to Order Your High Volume
PCB Assembly in 5 Easy Steps
Submit Your PCB Design
Upload your Gerber files or use our easy online PCB design tool to create your board layout. Make sure your files are complete and correctly formatted to ensure smooth processing and production accuracy.
Select Your PCB Specifications
Customize your order by choosing the technical specifications—number of layers, board dimensions, thickness, copper weight, solder mask color, surface finish, and more. Our intuitive interface helps you configure everything based on your project’s needs.
Get an Instant Quote
Once your design and specs are in place, you'll receive a transparent, instant quote. Pricing updates in real time as you modify options, so you can adjust your selections to match your budget before placing the order.
Confirm Order & Make Payment
Review your entire order for accuracy, including file previews and selected specs. After confirmation, proceed to secure checkout and choose your preferred payment method. You’ll receive an email confirmation with order details.
Production & Delivery
Your PCB moves into production immediately. We’ll keep you updated throughout the manufacturing process. Once completed, your boards are carefully packed and shipped to your door, with tracking information provided for your convenience.
WellPCB is trusted by millions of
businesses and innovators.
Why Choose WellPCB?
WellPCB stands out among USA PCB manufacturers by delivering superior quality, advanced solutions, and unmatched reliability. With years of experience serving global markets, WellPCB has earned a reputation as one of the top PCB manufacturers in USA.
WellPCB specializes in multilayer PCBs for advanced electronic applications. You can order these boards with $100 off using our special offer, providing high complexity at competitive rates for demanding projects.
Hommer Zhao
Founder and Chief Editor – Hommer Zhao
Welcome! I’m Hommer Zhao, the founder and Chief Editor of WellPCB. With years of experience in the PCB industry, I’m committed to making sure our content is both accurate and helpful. We’re proud to serve a growing community of over 4,000 customers worldwide, and our goal is to provide you with the best resources and support. Your satisfaction is our top priority, and we’re here to help you every step of the way!
Jesse Holland
Technical Manager – Jesse Holland
Hi, I’m Jesse Holland, an Engineer and Technical Manager at WellPCB. With years of experience in PCB design and engineering, I’m here to ensure that every project we work on meets the highest technical standards. I lead our team, focusing on precision and innovation, collaborating closely with clients to provide tailored solutions and expert guidance. Whether you’re facing a complex design challenge or need advice on technical aspects, I’m here to ensure your project is a success from start to finish.
Nathan Jensen
Purchasing Manager – Nathan Jensen
Hi, I’m Nathan Jenson, the Purchasing Manager at WellPCB. I’m responsible for sourcing the best materials and components to ensure our products meet the highest quality standards. With my extensive experience in procurement, I work closely with suppliers to secure reliable and cost-effective solutions while maintaining strong relationships to support our operations. I aim to ensure every project runs smoothly by providing the resources needed to deliver on time and to your satisfaction.
Emma
Sales Manager – Emma
Hey, I am Emma, sales manager at WellPCB. I studied electronic science and technology at university and have served customers for PCB and PCB Assembly service for several years.
I enjoy communicating with customers and our technicians to solve problems, and customers always say, "It's great to have you onboard".
It is my pleasure and honour to be helpful. Contact me now, and you'll know.
Bella and Cassiel
Sales Representatives – Bella and Cassiel
We’re Bella and Cassiel, your dedicated sales representatives at WellPCB. With our extensive knowledge of the PCB industry, we’re here to provide exceptional service and support. We take the time to understand your unique needs and are always ready to offer tailored solutions and advice. Whether you need product recommendations, assistance with your orders, or simply have a question, we’re here to ensure your experience is smooth and seamless at every step.
Mandy and Wendy
Sales Representatives – Mandy and Wendy
We’re Mandy and Wendy, your friendly sales representatives at WellPCB. Passionate about helping our customers, we bring a wealth of experience in the PCB industry to provide you with the best solutions and service. We take pride in building strong relationships with our clients, understanding their specific needs, and offering personalised support to ensure their satisfaction. Whether you’re looking for advice, product information, or assistance with any part of your order, we’re here to make your experience as smooth and efficient as possible.
Our Team
Our skilled engineers and technicians bring expertise and precision to every PCB assembly project. Committed to quality, efficiency, and innovation, our team ensures every order meets the highest UL, IPC, ROHS & REACH standards, delivering reliable solutions tailored to your needs.
- Founder and Chief Editor – Hommer Zhao
- Technical Manager – Jesse Holland
- Purchasing Manager – Nathan Jensen
- Sales Manager – Emma
- Sales Representatives – Bella and Cassiel
- Sales Representatives – Mandy and Wendy
High Volume PCB Assembly Case Studies
PCB Manufacturing
An electronics client needed a high-density 8-layer PCB with tight design constraints. We delivered high-performance, reliable boards meeting strict electrical and structural requirements.
PCB Specifications:
- Layers: 8
- Board Thickness: 1.8mm
- Min. Line Width/Space: 3/3.5 mil
- Min. Hole Size: 0.2mm
- Min. Distance from Hole to Line: 0.13mm
- Inner Layer Copper: Hoz
- Outer Layer Copper: 1oz
- Surface Finish: Immersion Gold
The final board met all mechanical and electrical tolerances and passed electrical testing with 100% yield. This project shows our capabilities to handle complex, high-density multilayer PCBs with tight tolerances and strict quality standards.
PCB Assembly
A PCB design firm in Italy required short-run production of a complex board with both SMT and THT components. We managed the full assembly process, including component sourcing, PCB manufacturing and assembly, inspection, and shipping.
Project Details
- Service Type: PCB Assembly
- Location: Italy
- Client Type: PCB Design Company
- Total Units: 20
- Lead Time: Rapid turnaround for prototyping
- Assembly Type: SMT+THT mixture assembly
Our experienced production team worked closely with the client to verify the BOM, optimize the stencil and the board’s layout design. We completed and delivered 20 fully assembled units within the expected lead time, allowing the client to avoid delays and meet their customers’ delivery window. This case highlights our capabilities to support global clients with flexible, low-volume PCB assembly solutions.
PCB Assembly
This PCBA solution integrates a custom PCB with high-precision SMT assembly, tailored specifically for smart fingerprint lock systems. Designed for household appliances, it combines compact size, low power consumption, and reliable signal processing to support biometric recognition and secure user access.
Technical Specifications:
- Product Type: PCBA (PCB + SMT Patch)
- Application Product: Smart Fingerprint Lock
- Industry/Application: Home Appliances / Smart Home
- Assembly Process: Surface Mount Technology (SMT)+THT
- Function: Biometric signal processing, control logic
Client Feedback On Our High Volume PCB Assembly
As an R&D manager, I have had an outstanding experience working with WELL-PCB. For many years, our company has entrusted them with the production, assembly, and programming of the boards developed in our R&D unit, and they have consistently exceeded our expectations.
Hamid Reza Moshayedi
R&D Manager
Their work is very impressively perfect. Today, when they check our company PCB board after assemble. They found a fake short point which many engineers has never found in the past years. But that is just designed so. The PCB board quality is excellent. Their service is also excellent.
MikeZ
My friend introduced WellPCB to me, the first try, a little look forward to. I ordered a 47*72 10ps PCB, and I can’t wait to receive my PCB. So I used expedited service and received my PCB in three days. I tested and soldered the PCB, Quality is really good, silkscreen, plating also great.
Warren Cliton
High Volume PCB Assembly FAQs
What qualifies as a high volume PCB assembly order?
Any PCB assembly project with 1,000 or more units is considered high volume. Orders exceeding 10,000 units require dedicated production lines, locked BOMs, and pre-set soldering profiles to maintain consistency and reduce unit cost.
Can you support both turnkey and consigned BOM for volume PCBA?
Yes, we offer full turnkey PCB assembly service with sourcing from authorized distributors, as well as consigned and hybrid BOM models. All BOMs are reviewed for footprint compatibility, component availability, and RoHS status before assembly.
How do you maintain quality across large volume printed circuit board assemblies?
We use IPC-A-610 Class 2 or Class 3 guidelines, ISO 9001-certified process control, and digital tracking via IPC-2581. All assembly data, inspection logs, and reflow profiles are documented per lot, and serialized units are traceable throughout the production line.
Do you support design feedback before launching mass production?
Yes, we perform DRC and DFM checks before fabrication and assembly. Our team evaluates Gerber files, stencil data, and BOM structure to prevent solder mask errors, component interference, and assembly conflicts during scale-up.
Can you assemble both SMT and through-hole components on one board?
Yes, we support mixed technology assembly with surface mount components placed before through-hole soldering. Boards are processed using reflow ovens and selective or wave soldering systems based on layout, part types, and thermal constraints.
Get $100 Off Your First High Volume PCB Assembly Order
Get $100 Off Your First Order!
WellPCB delivers high-quality PCB assembly solutions at scale with fast turnaround, certified process control, and full BOM flexibility. Submit your files today to begin production with IPC-certified control and optimized workflow from layout to packaging.
Plus, $100 off your first high-volume PCB assembly project!
