For power electronics engineers, project managers and sourcing teams working with industrial power, automotive, battery and medical systems.
Mixed-technology PCB assembly for power supplies and control electronics
If your PCBs combine SMT, THT and high-power magnetics on a single board, you need an EMS partner that can keep everything on one process flow. TPS runs mixed-technology PCB assembly lines for power supplies and control boards, combining SMT, selective soldering and final testing under IPC-A-610 Class 2/3 criteria for long-life industrial, automotive and medical applications.
On this page you will see how our PCB assembly is organised, which equipment and standards we use, and what a typical project looks like from first Gerber files to a tested board on your production line.
What you get from TPS mixed-technology PCB assembly
Most power electronics boards are no longer “pure SMT” or “pure THT”. A single design can mix fine-pitch SMT controllers, through-hole magnetics, high-current bus bars and heavy connectors on one PCB. Mixed-technology adds reliability – but only if SMT and THT are planned as a single process rather than separate jobs.
TPS designs each assembly flow around your board stack-up, power density and lifetime requirements. Our manufacturing services include:
- SMT placement of fine-pitch ICs, logic and drivers down to small package sizes.
- THT soldering of transformers, chokes, high-current terminals and relays.
- Thermal management features such as press-fit pins, thermal vias and heat-spreader interfaces.
- Cleaning, conformal coating and handling rules selected for your environment.
Looking for full system assembly? Combine these boards with our integration solutions for cabinets and test racks.
How SMT and THT run together on our assembly lines
A typical power electronics board starts on our SMT line and then continues through THT and final assembly. The key is that we plan the thermal profiles, solder alloys and handling windows together, so one step does not damage what the previous one has achieved.
Surface-mount assembly for controllers and low-power stages
- Solder paste printing and 3D SPI: stencil printers and 3D solder paste inspection control volume and alignment on fine-pitch pads, especially for BGAs, QFNs and small passives.
- Pick-and-place: high-speed machines place logic ICs, drivers, gate-drivers, digital isolators and small power MOSFETs with ±0.05 mm typical accuracy.
- Reflow profile control: multi-zone reflow ovens adjust soak and peak temperatures so heavy copper planes and thermal pads solder reliably without overheating neighbouring components.
- ESD-controlled environment: grounded workstations, wrist straps and humidity control protect sensitive controllers and ADCs.
Through-hole and high-current assembly for magnetics and connectors
- Component preparation: leads on transformers, chokes and power connectors are pre-formed and cut to controlled length to protect plated-through holes.
- Wave or selective soldering: depending on panel design we use full wave solder or programmable selective solder nozzles to avoid heat-sensitive SMT areas.
- Hand soldering under controlled work instructions: special parts like very large transformers or shunt resistors are soldered manually following detailed solder-fillet and wetting criteria.
- Rework and repair: we follow IPC guidelines for local rework to keep quality consistent across series.
Already have a full system in mind? Our integration solutions team can design matching cabinets, wiring and test benches around these boards.
DfM and DfT reviews for power electronics PCBs
Many issues on power boards can be avoided before the first panel is even built. TPS offers Design for Manufacturability (DfM) and Design for Test (DfT) reviews that focus specifically on power electronics: creepage distances, copper balancing, thermal reliefs and test access for high-current rails.
What we check during DfM for power boards
- Creepage and clearance versus your target standards (for example IEC/UL requirements for industrial, automotive or medical applications).
- Pad sizes and thermal reliefs on high-copper layers so heavy pins solder correctly without excessive heat.
- Panelisation, fiducials and tooling holes for stable handling in SMT printers, pick-and-place machines and selective solder fixtures.
- Heat-spreader and cooler interfaces where PCBs mount directly on aluminium or copper coolers CNC-machined by TPS.
Design-for-test so you can debug faster
- Clear test pads for in-circuit test or flying-probe, even on dense controller sections.
- Defined power-up and functional test points for measurements such as efficiency, ripple and timing in your lab or at TPS.
- Optional boundary-scan / JTAG headers for complex digital or FPGA-based control boards.
Need a more complete redesign? See how TPS supports R&D cases and redesign projects before moving into EMS production.
Quality, inspection and IPC-A-610 Class 2/3
For power supplies and control boards in industrial, automotive, battery and medical systems, small workmanship issues can lead to big field failures. TPS therefore builds to IPC-A-610 workmanship criteria and can target Class 2 or Class 3 depending on your application requirements.
In-line inspection across the entire assembly process
- 3D SPI after solder paste printing to catch insufficient or excessive paste before components are placed.
- AOI after reflow to check for polarity, tombstoning, bridges, opens and missing components.
- X-ray inspection for BGAs, power packages with exposed pads and multi-layer vias where joints are hidden.
- Visual inspection using IPC-trained staff for solder fillets, lead wetting, board cleanliness and mechanical assembly.
Functional testing for power electronics
For power electronics projects we can add electrical functional tests that go beyond visual inspection:
- Basic power-up and smoke tests on DC or AC supplies.
- Measurement of output voltage, ripple, efficiency and protection features.
- Burn-in or thermal cycling where your project requires additional stress testing.
Need to go straight from manufacturing into certification? Combine this PCB assembly flow with our EMC & safety testing services and safety & compliance case studies.
Projects and industries we typically support
TPS focuses on power electronics for demanding applications. Mixed-technology PCB assembly is most often used together with our magnetics, coolers and cabinet wiring for the following sectors:
Industrial power and automation
PCBs for factory automation, motion control and test equipment often combine digital control with high-current power stages. We assemble boards for PLC cabinets, motor drives, test racks and ATE with attention to creepage distances, surge paths and serviceability.
Automotive and e-mobility electronics
With IATF-based manufacturing principles, TPS supports DC/DC converters, on-board chargers and charging infrastructure electronics at low to medium volumes. Assemblies can be combined with custom magnetics and coolers and then integrated into power cabinets for charging stations.
Battery systems and energy storage
Mixed-technology PCBs are widely used in industrial battery systems and DC power shelves. TPS builds control and power boards for DC UPS, battery racks and grid-scale storage, and can connect them with our EMS manufacturing for busbars, coolers and complete cabinets.
Medical and laboratory equipment
For medical and lab instrumentation, reliability and documentation are essential. TPS manufactures power and control boards for analysers, diagnostics instruments and lab automation equipment, following documented processes aligned with medical device expectations.
How to start a PCB assembly project with TPS
Whether you are moving a mature design into series production or still refining a prototype, starting with clear data and expectations saves time. A typical onboarding for mixed-technology PCB assembly looks like this:
- Share your design package: Gerber/ODB++ data, BOM, assembly drawings, test requirements and target standards (for example IEC/UL, automotive or medical).
- Receive DfM/DfT feedback and quotation: TPS proposes panelisation, test concepts and assembly options, then provides pricing and lead time.
- Build prototypes and first series: we run pilot builds with documented feedback and then ramp up to regular production with agreed inspection and testing.
FAQ about mixed-technology PCB assembly
- What information do you need to quote a mixed-technology PCB assembly?
- At minimum we need Gerber or ODB++ data, a BOM with manufacturer part numbers, assembly drawings, target quantities and the standards you are designing to. Test requirements and sample photos of existing builds also help us size the right process flow.
- Can TPS build both prototypes and series production on the same line?
- Yes. We can start with small pilot builds to validate DfM changes and then scale up on the same SMT/THT line once yields and test coverage are confirmed.
- Which IPC class do you usually build to?
- Most industrial and automotive-related work targets IPC-A-610 Class 2, while safety-critical or long-life projects can be specified to Class 3 after a technical review.
- Can you also manufacture magnetics, coolers and mechanical parts?
- Yes. TPS combines PCB assembly with winding, coolers, sheet-metal and cabinet wiring so you can receive tested sub-systems instead of loose parts. See our electronic manufacturing services overview for the full stack.
- How does TPS support EMC and safety certification?
- Our EMS teams work closely with the TPS Labs in Germany and the US. We can prepare boards and cabinets for EMC and safety testing, run pre-compliance campaigns and feed the lessons learned back into your PCB layout and assembly rules.
