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Month: November 2025

Wave Soldering vs Selective Soldering: Perfecting Your Electronic Assembly Process

Should you use the wave soldering process or the 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).

electronic assembly

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:

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 a 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.

wave vs selective soldering

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 the 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.

Wave soldering

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 of 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.

Selective soldering process

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 the 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
  • Dense 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.

electronic assembly using soldering

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.

The 8 Key Components of Membrane Switches

For most devices, membrane switch components are meticulously designed with the user in mind. Every time you check out at the grocery store or click a button on your TV’s remote control, you interact with membrane switches. Even when I’m typing out these words, I am opening and closing the electrical circuit in my keyboard via membrane switches.

So, what exactly is a membrane switch? Well, that’s what we’re here to explore. In this blog, we will go over the key membrane switch components, what they are, and how they contribute to the functionality and reliability of these essential interfaces.

Let’s dive right in!

The 8 Key Membrane Switch Components

From the top layer that you touch to the circuitry that carries your commands, each component plays a critical role. Whether you’re a product designer, an engineer, or simply curious about the technology behind everyday devices, understanding these components will provide valuable insights. So, let’s get into it.

1.) Graphic Overlay

membrane switch overlay

Now, this is the component you are most likely familiar with. The graphic overlay, also known as the faceplate or fascia, is the topmost layer of a membrane switch and serves as the interface between the user and the device. Typically, the overlay is screen-printed on durable polyester or polycarbonate materials.

The graphic overlay must withstand repeated use while providing clear and intuitive labels for the underlying buttons. It is customizable in color, texture, and design. Not only does this enhance the aesthetic appeal of the device, but it also ensures that the interface is user-friendly and easy to navigate.

2.) Mounting Adhesive

Next, the mounting adhesive layer secures the switch to the device’s control panel. This adhesive must provide a strong and durable bond, capable of withstanding environmental factors such as temperature variations, humidity, and mechanical stress.

Usually, the adhesive contains acrylic compounds that help ensure the membrane switch stays firmly in place throughout its time in operation.

3.) Tactile Layer

tactile dome layer on membrane switch

Membrane switch domes, also known as tactile domes, are critical for providing tactile feedback to the user. These domes are positioned beneath the graphic overlay and deform when pressed, creating a noticeable “click” that confirms the activation of the switch.

Usually, these are made from stainless steel or polyester. The domes come in a variety of sizes and materials, but metal is the popular choice. Overall, switch domes help enhance the user experience by providing a responsive and satisfying touch, which is crucial in applications where precise input is essential.

4.) Circuit Layer

printed circuit boards

The circuit layer forms the core of the membrane switch, consisting of conductive pathways that connect the switch contacts to the device’s electronics. Typically, this layer is made from flexible printed circuits (FPC) or printed circuit boards (PCB), which can be customized to meet specific electrical requirements.

Moreover, the circuit layer ensures that signals are accurately transmitted from the switch to the device. Therefore, a reliable circuit layer is crucial to ensure the membrane switch operates efficiently. There are three main options for circuitry material.

  • Silver: The most common choice is using silver conductive ink printed on polyester. It’s cost-effective and effective for standard membrane switches.
  • Copper: Ideal for complex circuitry, copper flex circuits allow for soldering numerous components, meeting diverse design needs.
  • Rigid Printed Circuit Board: Suitable for complex designs, this option supports more termination options. It typically involves printing silver ink on polyester, adding a contact surface of etched plated copper, and enclosing it in a PCB with epoxy insulation and a dielectric layer for protection.

5.) Circuit Tail

what are membrane switches

Next, the circuit tail is an extension of the circuit layer that connects the membrane switch to the device’s main circuitry. This flexible tail typically terminates in a connector that plugs into the control board for easy installation and replacement.

The design and length of the circuit tail are critical for ensuring a secure and stable connection, as well as for accommodating the physical layout of the device.

6.) Back Panel

Hallmark Nameplate control panel, membrane switch components

While the back panel is optional, it provides structural support to the membrane switch assembly, ensuring that all layers remain aligned and securely bonded. This layer can be made from rigid or flexible materials, depending on the application requirements.

Moreover, this component can be especially useful in demanding environments where the device may be subjected to mechanical stress and vibration.

7.) Display Windows

Display windows are clear or tinted sections of the graphic overlay that allow users to view underlying displays or indicators. These windows must be optically clear and scratch-resistant to ensure long-term visibility and performance. Properly designed display windows provide important visual feedback to the user, such as status indicators or numeric displays.

8.) Backlighting & Indicators

what are membrane switches

Finally, backlighting and indicators are essential for improving the visibility and usability of membrane switches in low-light conditions. These elements are integrated using various technologies, such as light-emitting diodes (LEDs), electroluminescent (EL) panels, or fiber optics.

Effective backlighting not only enhances the aesthetic appeal of the device but also ensures that the interface remains functional and easy to use in any lighting environment.

What Are Membrane Switches Used For?

membrane switch components

Now that you know the key membrane switch components, you will understand the impact of every button you press. The reality is that membrane switches are all around us.

Their durability, reliability, and ease of customization make them ideal for a range of products and environments. Here are some common uses for membrane switches:

  • Consumer Products – Many household devices, such as remote controls, microwave ovens, washing machines, and gaming consoles, incorporate membrane switches. Their slim profile and responsive touch make them perfect for everyday consumer products.
  • Medical Devices – The medical field utilizes membrane switches in equipment like diagnostic machines, hospital bed controls, and wearable health devices. Their sealed design helps maintain hygiene standards and ensures reliable performance in critical applications.
  • Industrial Controls – Membrane switches are essential in industrial settings for machinery controls, control panels, and equipment interfaces. Their resistance to harsh conditions makes them suitable for use in factories and other demanding environments.
  • Aerospace & Military – Due to their reliability and ability to withstand extreme conditions, membrane switches are used in aircraft controls, military communication devices, and navigation systems.
  • Automotive Applications – In vehicles, membrane switches are used for dashboard controls, infotainment systems, and keyless entry systems. Their ability to integrate seamlessly into complex designs while providing intuitive control makes them a popular choice in the automotive industry.
  • Fitness Equipment – Treadmills, exercise bikes, and other fitness machines use membrane switches for their control panels. Their resistance to moisture and frequent use makes them ideal for this application.

As you can see, there are many applications for these devices. By providing a reliable and user-friendly interface on countless devices, membrane switches prove to be integral to modern technology.

Trust a Certified Electronic Assembler for Your Membrane Switch Needs

When you need electronic assembly, it’s important to find a trusted partner that upholds quality, reliability, and durability in all of their products. A certified electronic assembler brings a level of expertise and precision that is essential for creating high-performance membrane switches.

At Hallmark Nameplate, we pride ourselves on being a certified electronic assembler with decades of experience in the industry. We leverage cutting-edge technology and adhere to the highest standards to deliver membrane switches that meet and exceed your expectations.

Our commitment to quality, precision, and customer satisfaction sets us apart as a trusted partner for all your membrane switch needs. Trust Hallmark Nameplate to provide you with durable, reliable, and high-performance membrane switches.

Visit our website to learn more and request a FREE quote!

6 Signs You Need A New Nameplate Design

From product alterations to brand changes, it is important to keep your company cohesive across the board. So, when your organization makes a significant change, you need to make sure to update the nameplate design so it reflects the changes.

Depending on the developments of your organization, you may not need a total redesign. But maintaining updated information on your new nameplate is crucial for continuity, clarity, and brand recognition.

So, are you wondering whether or not you need to update to a new nameplate?

Well, you have come to the right place. In this article, we will discuss 6 common reasons why organizations might need to update to a new nameplate.

Key Takeaways:

  • Update your nameplate design to reflect brand changes, product updates, or company mergers.
  • A refreshed nameplate strengthens brand recognition, transparency, and customer trust.
  • Stay competitive by keeping designs current with industry trends and regulations.
  • Consistent, accurate nameplates ensure compliance, clarity, and professionalism across all products.

Why Would I Need a New Nameplate Design?

As we will discuss later in the article, there are a number of reasons why an organization may need to update their nameplates. Some of the conceptual reasons are: to improve brand recognition, provide inclusivity, and prioritize transparency.

Improve Brand Recognition

To promote brand recognition, your company’s nameplates should be different from those of your competitors in the industry. Making your product design memorable or unique will help improve your brand recognition, thus driving more loyal customers to your company.

Since all of your company’s products most likely include your logo or company name, your nameplate should as well. Therefore, any changes to your brand that affect people’s ability to identify it from your competitors should be displayed on your company nameplate.

new nameplate design

Provide Inclusivity

Now more than ever, organizations are prioritizing inclusivity through different initiatives. For example, the Army recently approved its soldiers to wear a redesigned nameplate on their Army Green Service Uniforms.

This new nameplate will enable the display of accent marks and hyphens on uniforms for the first time in Army history. By authorizing diacritics and hyphens on nameplates, they are trying to show support for minorities in the Army and assist in the correct pronunciation of soldiers’ surnames.

Prioritize Transparency

As mentioned earlier, you may need a new nameplate if your company undergoes significant changes to its branding or products. Addressing these changes in your company’s nameplates will ensure that your brand is as transparent as possible.

Transparency is beneficial for many reasons. The main reason this transparency will help your company is that it facilitates customer loyalty. For example, Label Insight, a company that specializes in product analysis, found that “94% of all customers are more likely to be loyal to a brand when it commits to full transparency.”

Since the purpose of a nameplate is to provide information about an organization, equipment, or even a person, it needs to be accurate and easily discernible. This is why maintaining up-to-date information on nameplates is important for products and industries that experience frequent changes or improvements.

6 Signs You Need A New Nameplate

If you are wondering whether or not you need a new nameplate for your business, here are 6 common reasons why you might need to update your nameplate design.

1.) Your Organization Changed Its Logo

One of the most common reasons why a nameplate design would need updating is if the company changed its logo. Obviously, significant changes to the logo should be implemented on all the company assets, such as products, the website, email signatures, etc.

However, even changes that may seem minor, like the addition of a comma or a slight brand color alteration, need to be updated. By prioritizing consistent branding across the board, you are helping your organization generate accurate brand recognition.

2.) Product Changes or Alterations

When making changes to your products, such as adding new features or tweaking their composition, it is a good idea to update the nameplate. Redesigning your nameplate to reflect these changes will promote your brand awareness and highlight your company’s transparency.

It will also ensure that your company is consistent and up to date with the descriptions of products and services on the market. So if your product has matured, then it is probably time for a new nameplate.

3.) You Merged With Another Company

If your company recently merged with another company, it might be time to update to a new nameplate. Mergers can often create a new identity for an organization, so your nameplate should mirror this identity change with updated branding.

Also, if the merger leads to an influx of new products, then you will want to make sure all of the products are implemented with the correct, redesigned nameplate.

4.) Product Line Expansion

Product expansion is often a result of a company merger. Since the new products that you acquired during the merger may not have the proper nameplate or accurate description, you will need to apply a new nameplate to the products that are added to your product line.

Some factors to take into consideration for product line expansion are model or product numbers, safety information, and manufacturing dates that will appear on the new nameplate design.

food service labels and food name plates

5.) Your Competitors Updated Their Nameplates

In order to keep up with your competition, you want to avoid being associated with outdated products, technology, and equipment. This is why it is important to be mindful of what your competitors are doing.

As we mentioned earlier, making your company stand out among its competitors will improve brand recognition and generate more loyal customers. So, it is useful to keep up with your competitors and adjust your nameplates accordingly.

6.) New Regulations or Restrictions in Your Industry

Since the main purposes of nameplates are to provide product tracking information and safety instructions, keeping your nameplates updated is a crucial step toward preventing improper use.

If you lack the properly updated safety or instructional information on your nameplate, then you may be at risk of violating industry regulations. You could also be putting your organization at risk for a lawsuit if someone is injured using your product.

Whenever there are important changes made in the regulations of your industry, your nameplates should reflect that information.

automotive labels and nameplates

As you can see, there are plenty of reasons why an organization may need a new nameplate. If you are wondering how you can get a new nameplate, we can help!

Upgrade Your Nameplate With Hallmark Nameplate

For more than 60 years, Hallmark Nameplate has been a trusted manufacturer of nameplates and custom metal fabrications. We serve numerous industries, including medical, aerospace, automotive, IT and computer, food service, and more.

If you have a certain order you need guidance on, we are happy to offer our expert advice to help you through the process. We also offer product sample boxes, so you can get the real look and feel for your nameplate.

So, let Hallmark Nameplate give you the quality and care you deserve. Visit our website or call 352-383-8142 to request a free quote.