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Tag Archive: prototyping

  1. A Complete Prototyping Checklist for Printed Circuit Boards (PCBs)

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    The pillars of quality electronic manufacturing are precision, reliability, and functionality. Each project must meet a specific performance standard, and printed circuit boards (PCBs) are critical in gauging whether a project has succeeded or failed. PCB assembly systems risk becoming unreliable, imprecise, and nonfunctional without proper manufacturing. Prototyping is an essential step to guarantee these products function as planned. In effect, this blog breaks down the prototyping checklist and the benefits of the process. 

    Benefits of Prototypes

    benefits of pcba prototypingPrototypes for PCBs help prevent potential issues with the end product. Prototyping offers numerous advantages, such as:

    Trained Eye Inspection

    Firstly, multiple tests at every step ensure the project meets the original vision. In practice, tests involve a trained eye inspection of the product’s design, followed by specific testing methods, including automated optical inspection (AOI), solder paste inspection (SPI), and X-ray evaluations.

    Supreme Time-Saver and Performance-Checker

    Testing individual components enable manufacturers to pinpoint areas of failure in designs accurately. This process is critical, as a single defective piece is detrimental to a project. Simultaneously testing each feature helps optimize performance and save time.

    Open-Line Discussion with Manufacturer

    Prototype assemblies entail open communication with manufacturers. If certain areas require more focus than others, it’s easy to connect with the manufacturer to relay this need. Manufacturers will break down references, product life, component cost allocation, and documentation. Additionally, they can troubleshoot any problems that develop.

    Early Discovery of Design Problems

    Prototypes help ease the consequences of errors by providing sufficient time to fix design flaws or readjust concepts. This benefit stops issues from becoming more critical as manufacturers produce higher volumes, preventing resource waste and project delays.

    Reduce Added Costs

    Another benefit of prototyping is the ability to discover pitfalls on the road map instead of detecting fatal flaws at a later time. This step saves more money by ensuring successful production and replication.

    Shorten Project Timeline

    Prototyping helps avoid the winding roadblock and U-turns that could otherwise lengthen a project’s timeline. When developing new product designs, their impact on a given industry depends on their timing and effectiveness. 

    Prototyping Checklist for Success

    To help you get started on your next project, here’s a prototyping checklist that will guide you through each step to ensure your project’s success. These steps are as follows:

    1. 1. Send initial documents and design specifications
    2. 2. Receive feedback from PCBA manufacturers on the company and  initial machine compatibility
    3. 3. Receive a review of the bill of materials with a focus on end-of-life components
    4. 4. Review the visual model of the design with the manufacturer to ensure the project is feasible
    5. 5. Make any necessary adjustments to the PCBA design
    6. 6. Review the proof-of-concept (POC) with the manufacturer for a final check of feasibility
    7. 7. Make additional adjustments to the PCBA design as needed
    8. 8. Review the performance of the working prototype with the manufacturer to check functionality
    9. 9. Make more adjustments to the PCBA design if required
    10. 10. Review the functional prototype with the manufacturer for a final check of functionality
    11. 11. Make final necessary adjustments to the PCBA design
    12. 12. Greenlight the project for production

    pcb assembly guide to prototyping

    PCB Assembly and Prototyping at PGF Technology Group, Inc.

    If you require reliable PCB assembly and prototyping for a project, PGF Technology Group offers complete PCB assembly services to help fully realize your vision. We have worked with many customers across many industries, including:

    We’ll work with you to determine what you need for your unique project based on your specifications. We’ll then prototype the end product to ensure it’s fully functional and features an accurate and precise design. Contact us today to get started on your next project with us or learn more about our services

    Contact Us

  2. Cables and Wire Harnesses: What’s the Difference?

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    What Is the Difference Between a Cable Harness Assembly and a Wire Harness Assembly?

    Cables and wire harnesses are both responsible for supplying electrical components with power, organizing cables and wires to optimize space, and providing them with some manner of protection from environmental conditions. Despite their functional similarities, however, these assemblies are not interchangeable. Each has its unique advantages and optimal applications. At PGF Technology Group, Inc., our team can assist you in finding the right assembly for your project.

    Just as these assembly types are two different products, the same is true of wires and cables. A wire is a strand of electrically conductive metal like copper or aluminum that can transmit power as well as information. A cable, then, is made up of multiple wires that are usually joined in a braided or bonded configuration.

    The key variation between the two assemblies has to do with how protected their cables or wires are from chemicals, moisture, dust, extreme temperatures, and friction.


    Cables vs. Wire Harnesses

    Cable Assemblies

    Cable assemblies bundle wires or cables together for organization and efficient electrical system operation. Of the two assembly types, cable assemblies are best suited to outdoor applications. They are superior for withstanding environmental stress because they utilize a durable cover of materials such as vinyl, thermoplastic rubber, or shrink-wrapped thermoplastic. This robust insulating sheath safeguards internal cables from high heat, dirt, or other contaminants, detrimental weather, compressive force, abrasion, and more. 

    Wire Harnesses

    Wire harnesses work well as cable system organizers, particularly in grouping smaller internal wires or cables for added connectivity. However, while these assemblies do include a protective casing to prevent short-circuiting in the wiring, it is far less rugged than a cable assembly cover. Instead, the grouped cables and wires in wire harnesses typically have their outer coverings already for that protection. While the assembly does group them in one harness, their sheaths still make it easy to see individual cables. Additionally, these individual sub-assemblies allow for highly complex projects that are adaptable for many unique uses. The harness’ simple outer sheath of thermoset materials or thermoplastic helps protect the wires and cables from their environment for indoor applications.


    Looking for a prototype cable or wire harness solution? Make sure to download our free eBook.

    Cable Assembly and Wire Harness Advantages

    Cable assemblies and wire harnesses increase organizational and spatial efficiency. They also improve operational safety by preventing electrical fires and taming loose wires. However, each assembly type has its advantageous qualities. The covers that jacket cable assemblies are durable and strong, enabling more versatile applications as they can withstand a wider variety of environmental conditions. Also, as the internal bundled wires are all contained within a single outer sheath, it makes them more accessible for threading within smaller areas.

    Wire harnesses are ideal for their ease of installation and simplified maintenance, resulting in reduced labor time. Providing less protection, wire harnesses work best indoors. This characteristic, added to their simplistic design, typically makes them more affordable. Also, the outer covering will still safeguard against moisture or chemical solvents.


    Applications of Cable and Wire Harness Assemblies

    Given the assemblies’ strengths, wire harness and cable assembly applications are varied, spreading across diverse industries.

    Cable Assembly Applications

    Cable assemblies organize or facilitate safe wiring in the following applications:


    • Flight Simulators
    • Ground Equipment
    • In-Flight Medical Systems
    • Links for Field Communication 
    • Remote Control Weaponry
    • Navigation Systems
    • Rugged Computers


    • Cockpit Instruments
    • Drones and Unmanned Aerial Vehicles (UAVs)
    • Electronic Systems for In-Flight Entertainment

    Automotive and Transportation

    • Data Transmission Systems
    • High-Voltage Current Transmissions
    • Navigation Systems


    • Audio Systems
    • Communication Systems
    • Flat-Panel Displays

    Wire Harness Applications

    Wire harnesses allow for orderly wire organization in:


    • Aircraft Power Transmission
    • Airplane Engines
    • Communications Systems
    • Drones
    • Satellites


    • Dashboards
    • Lighting and Turn Signals
    • Navigation Systems
    • Engine Bays


    • Crash Carts
    • Dental Equipment
    • Diagnostic Equipment
    • Imaging Equipment

    Robotics and Automation

    • Assembly Line Systems
    • Automated Computer Numerical Control (CNC) Machines
    • Computerized Systems, Servers, and Electronics
    • Data Transmission
    • Power Distribution

    Cable and Wire Harness Solutions from PGF Technology Group

    At PGF Technology, we pride ourselves on providing high-quality, cost-effective wire harnesses and cable assemblies for industry compliance in some of the most demanding electrical applications. Backed by over 50 years of ISO-certified design and manufacturing experience, our team can work with you to determine your installation requirements, space limitations, power needs, and environmental challenges to develop a reliable assembly solution tailored to your specifications.

    Our comprehensive capabilities for residential, industrial, and commercial applications include:

    • Product development
    • Prototyping
    • Design and Inspection Support
    • Fabrication and Manufacturing
    • Turnkey Component Assembly

    Partner with PGF Technology

    Determining the appropriate cable and wire harness assembly for your application will keep your systems and workspace organized, compliant, and functioning efficiently. PGF Technology specializes in assembly creation, with capabilities for C-Track cables, D-Subminiature cables, motor cables, sensor cables, data link assemblies, potting, and more. Contact us to learn about our electronic manufacturing solutions, or request a quote today.


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