EN
Choosing the right PCB assembly method is a key decision in electronic product development. Whether you're building a smart EV charger, a Bluetooth-enabled medical device, or an industrial sensor system, your choice between SMD board assembly and traditional PCB assembly can significantly impact performance, cost, and reliability.
In this article, GreensTone breaks down the differences between these two methods, so you can determine which approach best suits your product requirements.
SMD stands for Surface-Mounted Device. SMD board assembly refers to the process of placing and soldering surface-mount components directly onto the surface of a printed circuit board (PCB). Unlike traditional methods, SMD components do not require drilled holes; instead, they are secured with solder paste and reflowed using heat.
SMD board assembly is the foundation of most modern electronics manufacturing, thanks to its speed, efficiency, and suitability for compact, high-density designs.
Traditional PCB assembly—often referred to as Through-Hole Technology (THT)—involves inserting component leads through pre-drilled holes in the PCB and soldering them on the opposite side. This method has been in use for decades and is still favored in specific applications that demand stronger mechanical bonds or high durability.
THT is especially useful for:
Large components (e.g., transformers, connectors)
Products exposed to vibration or mechanical stress
Certain military, aerospace, or industrial-grade devices
To help you better compare the two assembly types, here's a breakdown of their main differences:
| Feature | SMD Board Assembly | Traditional PCB Assembly (THT) |
|---|---|---|
| Component Mounting | On PCB surface | Through drilled holes |
| Size & Weight | Smaller, lighter | Larger, heavier |
| Assembly Speed | Faster, automated | Slower, more manual |
| Design Density | High-density possible | Lower-density layouts |
| Mechanical Strength | Moderate | Higher (for stress-bearing parts) |
| Repairability | More challenging | Easier for manual rework |
| Common Use Cases | Smart home, wearables, consumer electronics | Automotive, industrial controls, heavy machinery |
SMD assembly is widely used in today’s electronics for a reason. Its advantages include:
Compact Design: Ideal for miniaturized products like smart plugs or wireless sensors.
High-Speed Production: Suitable for high-volume manufacturing, reducing time-to-market.
Cost Efficiency: Reduced labor and material costs due to automation and smaller components.
Improved Signal Integrity: Shorter electrical paths reduce noise and interference.
At GreensTone, we implement state-of-the-art pick-and-place machines and reflow ovens to ensure precision and consistency in every SMD board assembly we deliver.
Despite the dominance of SMD, THT remains relevant—especially in:
Power-intensive devices like industrial power controllers
Heavy-use environments with frequent vibration or physical force
Products requiring field serviceability, where manual repair is needed
Hybrid boards, where SMD and THT coexist
In fact, many of our clients in the automotive and industrial machinery sectors opt for a mixed approach—leveraging SMD for core circuitry and THT for connectors or power terminals.
In many real-world projects, it's not a matter of choosing one over the other but rather combining both. Known as mixed technology assembly, this approach integrates SMD and THT to optimize board performance, durability, and manufacturing cost.
Example Use Case:
A smart industrial water meter might use:
SMD for processing, communication modules, and sensors
THT for external connector pins and mechanical mounting points
At GreensTone, we’re experienced in hybrid assemblies and offer both SMD board assembly and through-hole soldering under one roof.
Here are a few questions to guide your decision:
Is your product space-constrained? → Go with SMD
Does it need to withstand mechanical shock? → Consider THT
Are you producing in high volume? → SMD offers better scalability
Does it need manual rework or maintenance in the field? → THT may be easier
Want the best of both? → Use a hybrid solution
At GreensTone, we understand that every product is unique. That’s why we provide flexible assembly solutions—SMD, THT, or hybrid—tailored to your specific industry and application. Whether you’re launching a new consumer gadget or building robust medical equipment, our expertise ensures your boards are manufactured with precision and care.
We offer:
Full turnkey PCB assembly service
SMD and through-hole capabilities
Component sourcing from certified suppliers
Testing options (AOI, X-ray, functional)
Molding and final product integration services
We’ve successfully served projects in EV charging, RF/Bluetooth modules, smart home devices, medical equipment, security systems, new energy products, and beyond.
Choosing between SMD board assembly and traditional PCB assembly isn’t about right or wrong—it’s about what’s right for your project. By understanding the strengths and trade-offs of each, and working with a trusted partner like GreensTone, you can bring your designs to life with confidence and efficiency.
