The customer approached us after facing repeated setbacks with other design houses that failed to deliver results. They were struggling with an outdated through-hole technology (THT) design, high manufacturing costs, and limited production capacity. Our solution enabled them to transform their manufacturing process, optimize costs, and scale production significantly.
Challenges
The customer’s existing THT-based PCBA design posed several challenges:
Bulky Design: The THT components increased the size of the PCBA and the overall product.
High Manufacturing Costs: The large size and manual assembly of THT components led to excessive production expenses.
Low Scalability: The existing design restricted production to only a few thousand units per month, unable to meet growing demand.
These challenges limited the customer’s ability to compete effectively in the market.
Our Approach
Our team worked closely with the customer’s design team to deliver a tailored solution:
We helped convert the existing THT design using our expertise in manufacturing and scalability to surface-mount device (SMD) technology, which significantly reduced the size of the PCBA and the overall product.
The new SMD design enabled automated manufacturing processes, reducing production time and costs.
We ensured the design was optimized for scalability, allowing for high-volume production without compromising quality.
Throughout the process, we maintained open communication with the customer’s team to ensure smooth implementation and alignment with their goals.
What We Achieved
The impact of the transformation was profound:
Reduced Product Size: The switch to SMD components minimized the size of the PCBA and the end product, improving its market appeal.
Lower Manufacturing Costs: Automation and a streamlined design led to significant cost savings for the customer.
Increased Scalability: Production capacity skyrocketed from a few thousand units per month to several million units per month.
Improved Market Competitiveness: The customer was able to offer better pricing to end users, boosting profitability and market share.