Electronic – Replace SOT-23 (5 pin) package in production with wire

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I have found a hardware bug on a board design after many PCBs have been manufactured but not populated. I can fix the problem by removing a SOT-23 component and putting a wire across two of the pads.

I have too many PCBs manufactured that manually installing a wire across the two pads of the removed component is not economical in time or money.

How can this be fixed using an automated production method? Are there components available to fix this kind of problem, i.e. a package with just a wire between the two pins?

Edit:

The link in question is one of the SOT23-5 diagonals.

One suggestion is to use a zero ohm resistor. These typically come in rectangular packages with rectangular leads.

Would a pick-and-place machine handle resistors placed at 45 degrees to the pads?

What would happen during reflow? Would the surface tension due to the incorrect alignment of the leads to pads cause the resistor to spin and detach from the intended pad?

Best Answer

You can buy zero Ohm links in a SOT23 package. Various connections are available, have a look at http://www.topline.tv/SOT_jumper.html