BGA PCB Assembly Services , High End Ball Grid Array Assembly

DuxPCB delivers high-end Ball Grid Array (BGA) assembly services, specializing in the most challenging footprint technologies. From standard FPGAs to complex Micro-BGAs (0.2mm pitch) and Package-on-Package (PoP) stacking, we possess the equipment and process maturity to ensure reliable interconnections.

The challenge with BGA technology is visibility. Since the solder joints are hidden beneath the package, visual inspection is impossible. Reliability depends entirely on process control. DuxPCB utilizes Nitrogen (N2) Reflow, 3D X-Ray Inspection, and proprietary thermal profiling to mitigate hidden risks like Voiding and Head-in-Pillow defects.

In BGA assembly, what you can't see can kill your product. We address the three most common BGA failures through rigorous engineering.

Voids in BGA balls reduce thermal conductivity and mechanical strength.

• The Industry Standard: IPC-A-610 Class 2 allows up to 25% voiding area.

• The DuxPCB Standard: We optimize our reflow profiles to target < 15% voiding (Class 3 requirement). We use Vacuum Reflow ovens and Nitrogen atmosphere to minimize oxidation and outgassing, ensuring solid, void-free joints.

HiP occurs when the solder ball rests on the paste but fails to coalesce, creating an open circuit that often passes electrical testing but fails later under vibration.

• Our Solution: We conduct regular solder paste inspection (SPI) and use high-activity flux chemistries. Most importantly, we verify component coplanarity to ensure the ball sits perfectly in the paste during the liquidous phase.

Large BGA packages warp during heating, lifting corners and causing open circuits.

• Our Solution: We use custom Magnetic Support Fixtures in the reflow oven to keep the PCB perfectly flat. For extremely thin boards, we design specialized pallets to prevent sagging.

We are equipped to handle the full spectrum of Area Array packages.

BGA assembly requires a tighter process window than standard SMT.

Step 1: DFM & Pad Design Review
Before manufacturing, we review the BGA "Dog-bone" or "Via-in-Pad" designs. We check if the solder mask dam is sufficient to prevent solder bridging between pads.

Step 2: Precision Stencil Printing
For fine-pitch BGAs, standard stencils fail. We use Electro-Polished or Nano-Coated stainless steel stencils with optimized aperture ratios (typically 0.9:1) to ensure perfect paste release.

Step 3: Component Placement
Our Pick & Place machines utilize high-resolution vision systems to recognize the BGA solder balls (not just the body outline) for alignment, ensuring the component is centered exactly on the pads.

Step 4: Nitrogen Reflow Soldering
The board enters a 10-zone reflow oven. We inject Nitrogen (N2) to lower the Oxygen PPM level. This improves wetting performance and significantly reduces the "Grape Effect" (non-coalesced solder) on micro-BGAs.

Step 5: X-Ray Verification
Every BGA board undergoes X-Ray inspection. We analyze:

• Bridge/Shorts: Checking for solder connecting two pads.

• Void Percentage: Calculating the exact void area.

• Alignment: Verifying the ball is centered on the pad.

PoP technology stacks a memory chip directly on top of a processor to save space and improve speed (common in smartphones). DuxPCB is one of the few EMS providers with mature PoP Assembly capabilities.

• Process: We use a specialized "Dipping Unit" to dip the top component's balls into flux or paste before placing it on top of the bottom component.

• Control: This requires extreme precision in Z-axis height control and reflow profiling to ensure both layers solder simultaneously without collapsing.

Mistakes happen (e.g., wrong firmware version inside a BGA, or a design error). DuxPCB offers professional BGA Rework Services.

• Desoldering: Using a programmable hot-gas nozzle to melt the solder without overheating adjacent parts.

• Site Dressing: Cleaning the PCB pads using a vacuum desoldering tool, leaving a flat surface.

• Reballing: Applying new solder spheres to the removed BGA component if it needs to be reused.

• Replacement: Placing a new BGA using split-vision optics to align the balls with the PCB pads.

Q: Do you use Type 3 or Type 4 solder paste for BGAs?
A: For standard BGAs (pitch > 0.5mm), Type 3 is sufficient. However, for Micro-BGAs (pitch < 0.5mm), DuxPCB standardizes on Type 4 or Type 5 paste. The smaller powder particle size ensures consistent paste release from tiny stencil apertures.

Q: How do you handle Via-in-Pad designs for BGAs?
A: If your design uses Via-in-Pad (common for 0.4mm pitch), we require the vias to be capped and plated over (VIPPO) or filled with resin. Open vias will wick solder away from the joint, causing voids or open circuits.

Q: Can you apply Underfill to BGAs?
A: Yes. For handheld devices or high-vibration automotive boards, we recommend Underfill. We dispense a liquid epoxy capillary under the BGA after reflow, which cures to lock the BGA in place, dramatically improving drop-test survival rates.

Q: What is your X-Ray sampling rate?
A: For prototypes, we inspect 100% of BGAs. For mass production, we perform 100% inspection on the first article and then follow an AQL (Acceptable Quality Level) sampling plan, or maintain 100% inspection depending on client requirements.

Don't let complex footprints limit your design potential. Partner with a manufacturer who understands the physics of fine-pitch assembly.

Send your Gerber files and Stack-up details to DuxPCB. Our CAM engineers will provide a free DFM review to optimize your BGA fan-out and stencil design.