Through Hole Assembly

Through-Hole PCB Assembly for Rugged, Reliable Prototypes

Benefits in Prototyping and Industrial Devices

Our Manual and Assisted Assembly Process

Through-Hole PCB Assembly for Rugged, Reliable Prototypes

At ProtoLab, we offer through-hole PCB assembly for clients developing prototypes, pilot runs, and rugged electronic systems. Through-hole technology (THT) may seem traditional compared to surface-mount technology, but it continues to play a critical role in applications requiring mechanical durability, high-current paths, and long-term reliability. Whether you're building an EV charger controller, an industrial PLC, or a motor driver, our small-batch assembly services provide the reliability and flexibility you need.

What is Through-Hole Assembly?

Through-hole assembly is a method of mounting electronic components by inserting their leads into drilled holes on a printed circuit board (PCB) and soldering them to pads on the opposite side. This technique ensures strong mechanical bonds between the component and the board, making it ideal for high-stress environments.

While surface-mount devices (SMDs) dominate modern high-density electronics, through-hole components still offer advantages in applications involving:

High currents or voltages
Mechanical stress or vibration
Manual prototyping and quick swaps
Components not available in SMD form (e.g., large capacitors, relays, connectors)

Benefits in Prototyping and Industrial Devices

Through-hole components are especially advantageous during prototyping for their ease of handling, reworkability, and availability. In industrial and automotive electronics, through-hole assembly continues to be used for critical parts such as:

Terminal blocks
Transformers
Power resistors
High-current relays
Large connectors and switches

For clients building low-volume hardware that needs to survive real-world stress—like EVSE systems, power supplies, and custom PLC boards—through-hole soldering provides peace of mind that the mechanical and electrical connections will endure.

Our Manual and Assisted Assembly Process

We tailor our through-hole assembly process for prototypes and small batches, emphasizing flexibility and quality. Our compact team uses a combination of:

Manual soldering for precision and rework
Custom jigs to speed up repetitive steps
Selective outsourcing for wave soldering or conformal coating (when required)

Each board is assembled with attention to polarity, thermal relief, component clearance, and pin trimming. We can work directly from your BOM, Gerber files, and 3D views to resolve potential layout or spacing issues before assembly begins.

Inspection & Testing

After assembly, we apply a thorough quality check process:

Visual inspection for solder quality, alignment, and residue
Continuity and short checks using multimeters or custom testers
Functional testing (optional) using client-supplied test procedures

We often integrate this testing phase with our device prototyping services, ensuring you receive not just assembled PCBs, but verified subsystems ready for system integration.

Ready to Build Your Prototype?

If you need rugged and reliable assembly for your prototype or small-batch product, ProtoLab SRL is here to help. With a deep focus on design-led engineering and flexible low-volume production, we’re ready to be your hardware development partner from idea to functional board.

📩 Contact us today to get a quote or discuss your next project.
🔧 Let’s turn your schematic into a working device—safely, reliably, and fast.

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