Should you use the wave soldering process or selective soldering process in electronic assemblies? The answer depends on the intended use of your PCB.

As electronic devices get more complex, so do their electronic assemblies. So, what are the different ways to create a strong electronic assembly and how can you keep up with the more advanced components and their requirements? The answer lies with soldering.

Simply put, soldering is a term that describes a process that uses a metal alloy to create a strong permanent bond between elements in electronic assemblies, such as a circuit board.

In this article, we’ll dive deeper into the world of electronic assemblies and soldering, and learn:

• What is an electronic assembly
• Proper ways to create circuit boards
• Key differences between the wave soldering process vs the selective soldering process

Let’s start by defining the purpose of electronic assemblies and some of their uses.

What is an Electronic Assembly?

Custom electronic assemblies, also known as printed circuit board assemblies, involve mounting components to the wiring of a printed circuit board (PCB).

The PCB is the foundation of electronic devices. A PCB has pathways that connect electronic components to transfer electricity. Additionally, it provides support for your components.

There are two main ways to create circuit board assemblies:

• Surface Mount Technology
• Through-Hole Technology

Depending on the type of PCB assembly different soldering processes will be used.

Soldering Processes for a PCB Assembly

There are two main soldering techniques when creating custom printed circuit board assembly:

• Wave soldering
• Selective soldering

You may be wondering what these two processes are and how they differ. Keep reading to learn the pros and cons of each.

Key Differences Between Wave Soldering & Selective Soldering

When choosing which process to use for your electronic assembly it is important to understand their differences. Each soldering process has its advantages and disadvantages that can affect the end product.

Let’s begin with what wave soldering is.

What is Wave Soldering?

Traditionally, the most popular solution for electronic assembly manufacturing has been to utilize wave soldering. This process, also known as flow soldering, has been the standard process for many years.

Flow soldering is ideal for projects that only require conventional through-hole components or those with particularly large surface mount components.

The Process

First, you spray a layer of the flux in order to clean the components of impurities.

Then you preheat the board to activate the flux. This also protects the board from thermal shock.

The PCB then passes through a molten wave making an electrical connection between the components and PCB. If you are soldering a double-sided PCB you will need to pass it through twice.

This process is performed in a protective nitrogen area in order to reduce any defects.

Pros of Wave Soldering

Wave soldering is perfect for simple soldering where you have a high quantity to do in a short amount of time.

The advantages to using flow soldering include:

• Easy setup
• Improved speed
• Cheaper process

While there are advantages to using the flow soldering process, it also has its disadvantages

Cons of Wave Soldering

While the setup is easy, post-cleanup takes longer because of the molten wave. It also may require additional reworking which, in the long run, can make the process more work.

Additionally, flow soldering requires more material, such as solder, flux, electricity, and nitrogen, to complete the process. Keeping up with the high rate of consumption can become expensive.

Next, let’s explain what selective soldering is.

What is Selective Soldering?

The other process is selective soldering. Selective soldering is a process where you solder individual through-hole components on a PCB using a solder fountain or head that moves to solder from underneath.

This method is becoming more and more common as the industry moves away from the assembly of larger PCBs of the past. Double-sided PCBs have become more common which use smaller components.

The Process

First, apply flux to the components that will be soldered. Then you preheat the board to activate the flux.

Then with an automated nozzle solder-specific components locally on an x-y gantry to the PCB.

Pros of Selective Soldering

Selective soldering is perfect for soldering small components on boards that are densely populated. As each section of the board is soldered individually, selective soldering is far easier to control.

Among other things, this makes it possible to adjust various parameters like thermal profiles, pitch, and component heights.

Other advantages of selective soldering include:

• Improves reliability of solder joints
• Removes the need for fluxing all components
• Less expensive
• Process optimization

Most importantly selective soldering provides consistency so you can easily reproduce the project.

Selective soldering is perfect for difficult conditions such as:

• Tall component height – tall components may block the wave from soldering
• Tight spacing – if a thru-hole component is close to an SMT component then there is not enough room for flow soldering
• Uneven heating – certain thick metals cannot be heated thoroughly enough to form a solid solder joint with the flow soldering
• Dence concentration – large connectors close together can make it difficult to reach the pins with wave soldering

As you can see there are a lot of advantages to using selective soldering which is why so many people are beginning to use it more. That being said there are still disadvantages to using selective soldering.

Cons of Selective Soldering

Like flow soldering, selective soldering also has some disadvantages.

For starters, the setup is more complex because it uses unique programming for every board

The soldering process is also more time-consuming than its counterpart and, therefore, is not efficient for producing high quantities.

Nevertheless, selective soldering is great for those who value precision and high-quality end results.

Create a Durable Electronic Assembly with Hallmark Nameplate

Whether you want to assemble your electronics through wave or selective soldering, Hallmark Nameplate ensures your soldering needs are professionally met.

At Hallmark Nameplate, we provide prototyping during our PCB assembly so you have peace of mind knowing that your electronic assembly exceeds expectations. Furthermore, for precise and efficient soldering, we use an Ersa Selective Soldering SMARTFLOW 2020. Not only that, but we also run several thorough tests including temperature humidity, thermal shock, and vibration testing.

Ready to start your electronic assembly? Our experts are always ready to help. Get in touch with us and we’ll find the right solution to meet your needs.

As of November 2020, 2.8 of every 100 full-time workers were injured at their workplace. With that being said, it’s common knowledge that hazards exist within almost every industry and business environment.

In order to protect your business and any parties involved, use a safety warning label, such as a machine warning label or a warning decal, wherever caution should be exercised.

In this blog, learn what a safety warning label is and its major benefits to the workplace. Then, discover 7 helpful tips that will allow you to create effective warning labels for your business.

First, let’s begin with the basics.

What is a Safety Warning Label?

You probably already know that companies have a duty to warn consumers and employees about the possibility of injury while using a specific product or machine. That’s where safety warning labels come into play.

Safety warning labels are the labels placed on many products that alert consumers about the dangers of using the specific product beyond its intended use. Warning labels can be placed on the product itself, as a nameplate, or be provided with the product in packaging materials.

Due to product liability law, there are many things that must be stated to absolve a company of any wrongdoing if a product was not used as intended, or if the consumer did not heed the information on the warning label. Therefore, it is up to the manufacturer to decide which type of label is best for their product and for the consumers who will be using them.

3 Common Types of Safety Warning Labels

For starters, there are 3 main types of safety warning labels. These are specific to their uses and have different components and requirements.

Keep reading to learn more about the types of warning labels you may encounter.

1. Facility and Building Warning Labels

This is the most common type of safety warning label. This type of safety label warns people of common hazards that might exist in and around your property.

2. Emergency and Fire Exit Labels

Next, fire safety labels are an important part of any business’s fire prevention equipment. Warning labels should always be designed in such a way that they are very noticeable, with large and brightly colored types.

These should feature not only type but also directional devices so that people understand where the exits are that the signs make them aware of.

3. Machine Warning Labels

Finally, it is important that any machinery with even the slightest chance of harming someone be labeled as a potential hazard. This includes any equipment that is heavy, mechanical, electrical or has the potential to give off heat.

These types of labels should be placed so that they are easily seen by anyone who is either using the equipment or even just walking past it.

So what are the benefits and purposes of these labels?

Major Benefits of Safety Warning Labels

From protecting your customers and employees to saving money, safety warning labels are used for several purposes and offer many benefits. For instance, some benefits include:

• Reduce the chances of accidents and injury – Whether a person is working in a given area or is simply a visitor, they should be aware that the potential for harm is present. The chances of avoiding payouts of workman’s compensation and damages from lawsuits are substantially lessened with the use of labels.
• Compliance – Warning labels and safety decals are required by OSHA. As a result, you should always label appropriate hazards in order to stay in compliance with local, state, and national requirements.
• Locating safety equipment – What good is having a fire extinguisher and other safety equipment if you can’t readily find it? A safety label can make everyone aware of the location of a piece of equipment that might otherwise be overlooked in the event of an emergency.
• Training and Orientation Benefits – Safety labels are an excellent way to make new employees and others aware of where safety equipment is located and how it is used to its greatest advantage. This is especially important for someone who might not be familiar with the dangers of your business areas.

In order to achieve the best results from your labels, you need to understand how to properly use the elements in a label.

Helpful Visual Elements That Benefit Safety of Use

Obviously, the better the signage is, the better the chances are that they will be seen and danger averted. There are 3 main visual elements you can use on your labels in order to help you deliver your message.

These visual elements include:

• Signal word – this is the one or two-word headline that captures attention
• Symbols – these are the pictograms you use to visually show your warning
• Word message – here is where you better explain the hazardous situation

In order to get the most out of your label, you need to know how to properly use these elements and create an effective design.

7 Tips for Creating Effective Safety Warning Labels

Your warning label isn’t helpful if your user cannot understand what it is trying to say. By following these 7 tips, you can create an effective safety warning label that protects your customers, employees, and your business.

1. Write Clear and Concise

In order to be sure that your warning is fully understood, it is recommended to write your warning clearly and concisely.

It is best to avoid any ambiguous or complicated wording and write in an active voice. You want to keep your message short and to the point so there aren’t any misunderstandings.

Remember to make sure everyone who may use the product or machine has access to the information on the label. This can be done by offering the label in other languages such as Spanish and French.

2. Select Signal Words

Your signal word is your headline that captures attention. There are several types of signal words you can use varying in severity. These include:

• Danger – The highest level of severity only meant for extreme situations that lead to death and serious injuries
• Warning – Warnings are for hazards that can end in death or injury
• Caution – Indicates that the situation can cause minor injuries
• Notice – This is for non-dangerous instructions and warnings
• Safety Instructions – Indicates that there are specific safety instructions

Once you choose your headline, you should pick a correlating symbol.

3. Use Pictograms & Symbols

You’ve probably heard the saying that a picture is worth a thousand words. Well the same goes for pictograms and symbols on safety warning labels!

Pictograms are one of the best ways to ensure everyone is aware of any hazards. Not only can they give a message at a glance but they are also universal and surpass language barriers.

When adding symbols, you want to make sure they are consistent and their meaning is clear. If there is any possibility of the image being misunderstood, you should follow it with a reinforcing message. This leads us to our next tip.

4. Include a Helpful Message

When an image isn’t enough information, include a message that explains what the warning is for and how you can work to avoid the hazard.

You can also include a message that explains any possible consequences of not listening to the warning. This helps motivate viewers to listen and understand the severity of their actions.

5. Pick a Durable Material

Next, your warning label is important to the safety of your customers and employees so you want to make sure it is durable. With that being said, you definitely don’t want your message to fade or get scratched.

Therefore, you should always choose a tough material that can withstand outside elements and chemicals.

While creating your safety warning label, it is important to understand and comply with standards that are set.

6. Choose the Best ISO Label Format

When it comes down to designing your safety warning label, you should also be aware of ISO (International Organization for Standardisation) label formats. For instance, common symbol-only styles include:

Yellow – Triangular warning signs to identify any hazards that can lead to injury
Blue – This circular mandatory action sign explains actions to take to avoid any hazards and stay safe. Typically contains white symbols in the blue circle.
Red – This label has a red circle with a slash across it. It is a prohibition label that shows you what actions are prohibited to avoid any danger.

Staying consistent with these styles can help improve users’ understanding and make it easy for those to notice warnings at a glance. Furthermore, compliance with these standards not only protects you but builds credibility with your customers.

Speaking of compliance…

7. Comply with Safety Warning Standards

To avoid liabilities and getting sued, you have to not only comply with state and federal regulations but also standards set by the following organizations. Here’s what you need to know.

American National Standards Institute (ANSI) – ANSI gives guidelines for creating safety signs for products inside the U.S. and Canada. Most warning labels use ANSI warning header for equipment warning labels, high voltage warnings on electrical utilities, and personal protective equipment. Using the pictograms you can easily grab attention and include clear consequences and avoidance statements.
Occupational Safety and Health Administration (OSHA) – OSHA danger headings are used on many danger labels for machinery warnings and Arc flash warnings. This type of label is more traditional and therefore has more familiarity amongst workers.
International Organization for Standardization (ISO) – ISO provides guidelines for safety labels that are typically used internationally, outside of the U.S. and Canada. They have symbol-only signs with three different styles for different purposes.

With these top 7 tips in your tool belt, it’s time to craft a custom safety warning label for your business.

Design the Perfect Safety Warning Label With Hallmark Nameplates

Whenever employees, guests, and others are on your property, you should make every effort to make sure that they are safe and know how to protect themselves when there is an emergency. Safety labels that are correctly made and appropriately placed are excellent for this purpose.

At Hallmark Nameplate, we have over 60 years of experience creating effective safety warning labels and know exactly what your project needs. We will work to not only meet your expectations but exceed them.

Ready to get started on creating your labels? Request a free quote today!