From automatic axial/radial insertion to wave and selective soldering — durable through-hole assembly for connectors, transformers, relays and power components that need joints stronger than SMT alone can deliver.
Wherever a joint needs to survive vibration, current or mechanical load. Hover to explore.
Connectors, relays and ignition coils hand- or wave-soldered for vibration-resistant, high-reliability mechanical joints under the hood.
Power supply connectors and terminal blocks in diagnostic equipment, built to IPC-A-610 Class 3 joint reliability standards.
Heavy-duty terminal blocks, transformers and contactors on control panel boards — wave and hand-soldered for years of continuous duty.
Power adapters, audio jacks and connectors needing manual or automatic through-hole insertion for durable everyday handling.
Power supply boards with high-current connectors for base station equipment, wave-soldered for reliable current-carrying joints.
Mission-critical connectors and relays hand-soldered to AS9100D and IPC-A-610 Class 3, with full pull-strength documentation.
Battery connectors and antenna mounts assembled for mechanical robustness where a plug-in connection sees repeated stress.
Transformers, inductors and high-current terminals for inverters and power converters — hand-soldered where mechanical strength is critical.
Through-hole joints carry mechanical load and high current that surface-mount alone can't handle. Every step below protects that reliability.
Leads are formed and cut to spec, components are verified against the BOM and moisture-sensitive parts are handled per J-STD-033 before they ever reach the line — preventing insertion errors and lead-related defects downstream.
BOM verification · lead forming · MSD handlingAutomated insertion machines place axial components (resistors, diodes) and radial components (capacitors) at high speed with repeatable ±0.1mm accuracy, reserving manual insertion for components that don't fit automated tooling.
±0.1mm insertion accuracy · axial & radial · high-speed sequencingWave soldering runs controlled pot temperature and conveyor angle for consistent barrel fill across double-sided and mixed-technology boards. On dense boards where through-hole components sit near SMT parts, selective soldering targets only the intended joints — leaving reflowed components undisturbed.
controlled pot temp · selective nozzles · mixed SMT+THTLeads are trimmed and formed to spec, and connectors, transformers, relays and large electrolytic capacitors are hand-soldered by J-STD-001 trained operators where extra mechanical strength or high current-carrying capacity is required.
J-STD-001 trained · connectors & transformers · mechanical strengthEvery joint is visually inspected against IPC-A-610 acceptance criteria, with pull-strength and mechanical robustness testing sampled per lot, followed by ICT or functional test as specified by the customer.
100% visual inspection · pull-strength sampling · ICT / functional testEvery insertion and soldering process runs in-house — no critical step is outsourced.
Automated insertion equipment handles axial components (resistors, diodes) and radial components (capacitors) at repeatable ±0.1mm accuracy, with manual insertion reserved for connectors and non-standard parts that don't fit automated tooling.
Precision wave solder machines run controlled pot temperature profiles and conveyor angle for consistent through-hole barrel fill across double-sided and mixed-technology boards, supporting both leaded and lead-free solder alloys.
Programmable selective soldering systems solder only targeted through-hole joints on densely populated mixed-technology boards, protecting nearby SMT components from the thermal stress a full wave pass would cause.
J-STD-001 trained operators at ESD-safe hand-solder stations assemble connectors, transformers, relays and large electrolytic capacitors that need extra mechanical strength, high current-carrying capacity, or simply don't fit an automated process.
Every parameter below is verified against IPC-A-610 through-hole solder joint acceptance criteria. Pull-strength and mechanical robustness reports ship with every order on request.
| Parameter | DIP / THT Assembly Spec | Status |
|---|---|---|
| Component Lead Diameter | 0.4mm – 1.2mm (axial/radial) | Available |
| Insertion Accuracy | ±0.1mm placement repeatability | Available |
| Wave Solder Pot Temperature | 250°C – 265°C, controlled ±2°C | Available |
| Selective Soldering Nozzle | 1.5mm – 12mm programmable nozzles | Available |
| Board Size Range | 50×50mm – 460×400mm (panel) | Available |
| Board Thickness | 0.8mm – 3.2mm | Available |
| Mixed SMT + THT Support | Yes — selective soldering standard | Available |
| Solder Alloy | Leaded (Sn63Pb37) & lead-free (SAC305) | Available |
| IPC Build Standard | Class 2 default · Class 3 on request | Available |
| Lead Time | 3–5 day standard / expedited on request | Available |
| MOQ | No MOQ on prototype assembly | Available |
Every through-hole joint is built and inspected against IPC-A-610 and J-STD-001 acceptance criteria, with pull-strength documentation available on request for connector, transformer and power-component assemblies.
Real DIP / through-hole assembly challenges — and how we solved them.
Wave-soldered power supply board with heavy-gauge terminal blocks and transformers for an industrial control panel manufacturer.
Consistent barrel fill across 8,000 boards with zero wave-solder related field returns; the customer eliminated their incoming solder-joint inspection step.
Dense automotive relay control board combining fine-pitch SMT components with through-hole relay sockets — selective soldering avoided reflow damage to nearby SMT parts.
Zero thermal damage to adjacent SMT components across a 15,000-unit run; the selective soldering profile is now used as the customer's reference process.
Large toroidal transformers and high-current connectors hand-soldered to IPC-A-610 Class 3 on a solar micro-inverter board.
100% pull-strength sample pass rate across 3 production lots; the customer's field return rate for solder-joint failures dropped to zero.
Through-hole assembly is chosen precisely because a joint needs to be stronger, or carry more current, than SMT alone can deliver. Our process is built around that requirement, not around it.
Wave, selective and hand-soldered joints are 100% visually inspected against IPC-A-610 acceptance criteria before a board ships — sampling isn't an option when mechanical strength is the point.
IPC-A-610 Class 2 is our baseline; Class 3 high-reliability build is available for automotive, aerospace and medical customers where every joint must survive the full product lifetime.
Solder joint pull-strength testing verifies that connectors, transformers and power components hold under mechanical load — not just that they pass a continuity check.
Standard THT and mixed-assembly lead time is 3–5 days, with wave, selective and hand-soldering scheduled in parallel — inspection and pull-strength sampling are never skipped to hit a date.
Common questions about DIP / through-hole assembly, soldering methods and inspection.
Wave soldering passes the entire underside of the board through a molten solder wave, ideal for boards that are purely through-hole or have SMT components rated for the wave process. Selective soldering targets only specific through-hole joints using a programmable nozzle, which is required when THT components sit close to SMT parts that would be damaged by a full wave pass. We'll recommend the right process at DFM review based on your layout.
Yes — mixed-technology assembly is one of our most common builds. SMT components are placed and reflowed first, then through-hole components are inserted and soldered using wave or selective soldering, chosen to protect the already-reflowed SMT joints. See our dedicated SMT Assembly service for the surface-mount side of the process.
Both. Automated wave and selective soldering handle the bulk of standard through-hole joints, but connectors, transformers, relays and large electrolytic capacitors that need extra mechanical strength or don't fit automated tooling are hand-soldered by J-STD-001 trained operators at ESD-safe stations.
All through-hole joints are built and visually inspected to IPC-A-610 Class 2 as standard, with Class 3 high-reliability build available on request for automotive, aerospace and medical applications. Every order can include a J-STD-001 compliant process record.
Yes. Pull-strength and mechanical robustness testing is sampled per lot on connector and power-component joints, verifying the joint holds under load — not just that it passes an electrical continuity check. Reports are available on request.
Standard lead time for through-hole and mixed-technology assembly is 3–5 working days from confirmed BOM and Gerbers, depending on component sourcing, hand-soldering content and volume. Expedited scheduling is available on request.
Our through-hole assembly team will review your BOM and layout and return a full DFM report and quote within 24 working hours.
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