Electronic – Holding components without bending leads when soldering upside down

pcb-assemblysolderingthrough-hole

I am gaining experience in soldering components onto PCBs. I'm working through some one sided through hole PCBs and one thing that I'm having trouble with is holding components once I flip the board. I generally tend to not like bending the leads when I flip the board. There are two reasons — one being that they still don't seem to fit tightly, not to mention you can't bend the leads of some components (e.g. short lead capacitors) and the second being that they don't solder on nicely. With bent leads, they can even sometimes be touching other soldering points in some cases (after cutting excess off).

The only thing stopping me from attaching all the components and then flipping it and soldering all the leads is that

  1. as soon as I flip it components fall out
  2. the components which are taller than others (e.g. electrolytics) dictate the other components to fall to that height.

The components falling out when I flip the board I can overcome by using a bit of card to hold them while I flip it. I experimented with some sponge to hold the components in their respective heights when I solder but not much success.

The best I can come up with is soldering in 'layers' with the shortest components first (resistors etc) and slowly building up until reaching the layer of electrolytic capacitors.But again, ideally I would like all the components on the board together and then just solder them all in one swipe.

Any better ways of doing this? Any pointers?

Best Answer

It isn't a solution to all through hole components, but for devices with more than two pins I've taken to designing my landing pads with hand assembly in mind. For instance, with header, the pins can be slightly offset so the pins fit snuggly in the PCB, like this:

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Each through hole has an alternating plus or minus 0.05 mm offset from the center (it's a 1.27 mm pitch header, or 0.05", half the normal 0.1" pitch that's so common). I've produced at least four boards with this augmentation and it works well for holding the header flush while I get it soldered. It even makes routing easier in some cases, like a 45° route from a pad where the adjacent pad is recessed will more easily meet clearance rules.

I haven't used any DIP parts recently, but if I did I would likely use a similar method to make hand assembly less of a chore.

For components with only two leads it's easy enough to tin the corner of one of the through hole pads and hold the component in place with one hand while the other wicks that bit of solder to lightly hold a lead of the component in place. Solder the other lead and then finish up the lightly soldered one.