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Nahaufnahme einer Platine mit Chips und weiteren Bauteilen

Individuality multiplied.

Customer-specific, custom-made production and innovative development solutions.

Reading time: 18 minutes

Perfectly happy – all along the line.

SMT assembly

SMT assembly for all batch sizes.

In addition to a high component density, SMT assembly also allows the miniaturisation of circuits and assemblies. fabsolutions SMD manufacturing services are carried out on high-speed automatic assembly machines for PCB processing with components from size 01005. In contrast to THT, there are no wire connections for surface mounting. Rather, the components are fixed directly on the printed circuit board by reflow process or wave soldering. The assembled printed circuit boards (PCBAs) then undergo an AOI and / or AXI test.


SMT at a glance.

  • High component density permits the miniaturisation of circuits and assemblies
  • PCB assembly on both sides is possible
  • Improved electrical properties of the circuit – especially at higher frequencies
  • Faster production thanks to pick-and-place
  • Increase in production quality through automatic PCB assembly
  • No pollution
  • Reduced throughput times through the use of Manufacturing Execution System (MES) software

SMT production is designed as an in-line concept and allows a high degree of automation – even for the high—volume production of the smallest components. In addition to the laser marking of the PCBs, it also includes solder paste printing, assembly, reflow or selective soldering with multi-wave, solder removal, AOI and ICT, as well as a separation robot that separates the elements from each other and provides them for packaging. All PCBs are fully traceable (traceability). Faulty printed circuit boards are detected by means of AOI and not processed further.

The right connection to the PCB.

THT assembly is also available for fabsolutions production technologies. Components with a high mechanical load, such as connectors, switches or power semiconductors, are rarely available in SMD designs.

We primarily equip wired components manually – supported by automatic processes of the pick-to-light system. Axially and radially wired components can be equipped automatically without restrictions. Also, with the fully automatic soldering processes (Through-Hole Reflow Technology), wired components can be soldered in the reflow oven, which eliminates cost-intensive manual or wave soldering.

All mixed printed circuit boards are tested using AOI.


Other soldering methods

  • Wave soldering
  • Selective soldering
  • Robot soldering
  • Laser soldering
  • Manual soldering

Well protected all-around.

Protection of electronics, as a rule, pursues several goals: The electronic components should be effectively protected from external influences such as vibrations, moisture, dust or even chemicals over the longest possible period of time. The aim is a long service life and the avoidance of complex maintenance and servicing. In short: It is important to save unnecessary costs. In addition, the electronic protection ideally fulfils other functional or aesthetic properties.

In certain applications, the protection of the electronics must also act in the opposite direction and ensure that no hazardous substances from the electronics enter the environment or the medium to be determined. In the case of a sensor, it must also be ensured that the electronic protection does not impair the signal quality. We offer different protection methods as part of the fabsolutions electronics production:

  • Immersion coating, selective coating, immersion selective coating (also ATEX-compliant)
  • Fluoropolymer coating
  • Encapsulation with polyurethane or epoxy
  • Direct over-moulding with polymers (also available as autoclavable over-moulding)
  • Housing assembly / Box Build

In any case, we adapt the electronic protection method and also the materials individually to your electronics. Functional and fastening elements are protected at the same time. 3D shaping and the production of housing parts are also part of our services. Finally, tests are carried out on the electrical manufacture and functionality offered by the protection.


Good electronic protection offers many advantages.

  • Improved thermal conductivity
  • Extended temperature range
  • Increased electrical insulation
  • Better heat distribution
  • Resistance to UV irradiation, abrasion and colour changes
  • Possibility of sterilising over-moulded assemblies with the help of direct over-moulding

Thinking into the box.

Box Build includes the integration of electronics and mechanics into an optimised device solution and means all assembly work on an electromechanical assembly – except for the assembly of the board. fabsolutions Box Build solutions are always customer-specific.

Our complex assembly options and production in our own tool shop, as well as the handling of all logistics, reduce interfaces (one-stop shop), the time needed and logistics effort, thus enabling a faster time-to-market. Our customers receive a complete solution including housing, required cables and – if desired – a customer-specific packaging solution.

During system integration, various housing materials are possible, monitored screwing technology ensures maximum precision during assembly. In addition, we have all the necessary test procedures and can also take over the programming and configuration of complete devices on request. Including connection of the assembled cables.


Box Build at a glance.

  • Assembly of devices and switchgear including assembly, functional and system testing
  • Housing construction
  • System and PCBA 3D modelling
  • Packaging, e.g. over-moulding and encapsulation technology
  • Electromechanics
  • Thermal dimensioning
  • Thermal management
  • Finite Element Mechanics (FEM) Simulation

Special tests – from the prototypes to the finished product.

Parallel to the increasing complexity of assemblies, the requirements for the test procedures are also increasing. At fabsolutions, we, therefore, use both optical, mechanical and electrical tests for quality assurance — depending on the type of electronics.

Optical tests

  • AOI Test: Automatic Optical Inspection – Automatic Optical Inspection
  • AXI Test: Automatic X-Ray Inspection – Automatic X-Ray Inspection

Electronic functional tests (universal tests or customer-specific)

  • Flying Probe
  • Functional Test – Functional Test (FCT)
  • Boundary-Scan Test – Standard procedure for testing digital and analogue components
  • In-Circuit Test – Electronic Circuit Test (ICT)

Safety Tests – High Voltage (HV) Special test System

  • HV Test for large-scale equipment
  • HV Test for control cabinets

Protective conductor tests – Module programming

  • Pre-programming of building blocks with specific adaptations
  • Marking of the building blocks with software version as laser marking or with label

A specific test procedure is part of the development and production of customer-specific electronics. For electrical tests, we develop and build special test equipment and program the appropriate test software.

Central data storage plays a major role in this: Data exchange, maintenance, backup and analysis are digitally backed up and are available on demand.


Inspection & Testing

  • Own adapter and test equipment construction
  • Special test stands for devices and systems
  • Central data storage
  • Acquisition and support of customer measurement technology

For devices and systems.

For the electrical test, we develop and build special test equipment and program the appropriate test software right away. This allows us to respond directly to the requirements of your application.


Test preparation

  • Special test stands for devices and systems
  • Customer-specific test adapters and test devices
  • Universal test stands for small devices
  • Various functional test stations on in-house developed test platforms (e. g.: UTS system, Reinhardt, Spwa and test stand [Labview])
  • Acquisition and support of customer measurement technology
  • System configuration, programming, parameterisation
  • Electrical tests
  • EMC test, environmental tests, high voltage, burn-in and climate tests
  • Documentation

Guaranteed production until the end.

We offer a special service within the fabsolutions production services at the Greifswald location: Here, we not only produce electronic components, but also take over complete production lines — for example, for the last three to five years of production. This is accompanied by the assumption of product production according to customer specifications

On the one hand, ml&s in Greifswald has the appropriate areas and, on the other hand, the necessary technical know-how to continue to operate older machines in a qualified manner. After completion of the production (EoL), the customer decides on the storage or scrapping of the machines.

Manufacturing begins with us in development.

The New Product Introduction (NPI) is one of the most sensitive processes that our customers go through together with us in fabsolutions. From the idea to the marketable product, i.e. within industrialisation, a large number of different steps are required for this. Ever shorter product and innovation cycles make it essential to complete these steps faster and more efficiently.

This places high demands on an EMS and E2MS service provider, regardless of whether they are high-mix-low-volume or low-mix-high-volume projects. With our cross-functional customer teams, which consist of purchasing, product development and project management, we realise your products with a short time-to-market and ensure short innovation cycles.


New Product Introduction

  • Optimal adaptation of circuit design, PCB carrier material and electronic components
  • Reduction of the number of components through functional integration
  • Selection of the optimal electronic protection
  • Minimum number of interfaces
  • Avoidance of adjustments
  • Increased use of modular systems

Customer satisfaction par excellence.

fabsolutions stands for Design for Excellence (DfX), i.e. the claim to adapt the constructive design of the product to the manufacturing, assembly and test processes with the best possible cost structure. "Production begins at duotec in development" is, therefore, meant quite literally: In close coordination with project management, our product development department adapts the electronic idea to series production in such a way that it can be manufactured as cost-effectively as possible with high quality standards.

fabsolutions takes the concept of Design for Manufacturing (DfM) even further: It is not only about high-quality and cost-optimised electronics, but also about high reliability and enormous longevity. For this purpose, we use our diverse application know-how, as well as our many years of expertise, in the development of electronic solutions for various – and sometimes even extreme – fields of application.

Manpower x 12.

An automated production cell supports us in the production of electronic assemblies and modules. Just the right keyword, because the single robot arm has six axes and forms the centre of a rotary indexing table. With the help of the automation cell, we can carry out handling processes as quickly and efficiently as possible — from testing and assembly, to gluing and welding to packaging and labelling.

But you don't have to decide, because the twelve available places are modular – that means: the equipment or the joining tasks are interchangeable. Only the master module and the module mounting plates belong to the base of the machine. In terms of speed and flexibility, we are setting new standards with the help of the production cell — and that's times twelve.


Production cell at a glance.

  • Modular system with 12 seats
  • Modules are interchangeable equipment
  • Master module as fixed equipment
  • 6-Axis Robot
  • Rotary indexing table
  • Module mounting plate as the basis of the machine
Ein Windpark mit vielen Windkraftanlagen vor wolkigem HimmelEin Windpark mit vielen Windkraftanlagen vor wolkigem Himmel

Far from civilisation and under the harshest weather conditions, constantly measuring data.

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