Many medical devices and life sciences instruments include optical subassemblies that contain LEDs, lasers and cameras, all of which require precision positioning to ensure optimal performance. Similarly, the electrical continuity of a PCB assembly (PCBA), and the integrity of each of its electronic components, can be the difference between a perfectly functioning device and a scrap product. That’s why we employ the following test methods to identify any potential issues:
- In-circuit testing (ICT): Our expert team can design bespoke ICT procedures and fixtures to suit every PCBA, no matter the complexity. We use Keysight 3070 platforms to automatically detect defective traces and solder joints – including using boundary scan testing to verify board-level connection issues – as well as to identify faulty, missing or incorrectly installed components.
- X-ray verification: PCBAs that are not flagged during the ICT process can still contain sub-par solder joints, which are functional but prone to failure over time. That’s why we use Vitrox V810i automated X-ray inspection systems to assess the integrity of every solder joint in three dimensions, allowing us to identify any contacts that need reworking.
- Optical inspection: We inspect every PCBA using Koh Young Zenith 3D automated optical inspection (AOI) systems which use a series of cameras to automatically assesses solder joint integrity and identify missing components, alerting the team to any damage or defects.
- Functional testing: We validate the performance of each component – including PCBAs, pumps, heaters, power supplies and sensors – against its functional requirements and design specifications. Once component verification is complete, individual subassemblies are integrated into the final product using our innovative vPoke® mechanical assembly system.
- System testing: Following assembly, the final device undergoes rigorous system testing – usually via a client specified application programming interface – to ensure that all essential product features are operational. This can include testing everything from USB ports and LEDs to vacuum systems and robotic arms, depending on the instrument. This final phase of testing gives our clients an added layer of confidence that every device coming off the production line will work exactly as intended.