Component Leads Too Short

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   Kind of a random question, what would be the best option to do if your through hole component leads are shorter than your pcb thickness?

And using other components is not an option for us.

Any suggestions would be greatly appreciated.

Thanks
Jesus

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Eng. Jesus Mora Members Profile Send Private Message Find Members Posts Add to Buddy List Advanced User Joined: 11 Jul 2013 Status: Offline Points: 56	Post Options Post Reply Quote Eng. Jesus Mora Report Post Thanks(1) Quote Reply Topic: Component Leads Too Short Posted: 05 Nov 2015 at 4:26pm
	Kind of a random question, what would be the best option to do if your through hole component leads are shorter than your pcb thickness? And using other components is not an option for us. Any suggestions would be greatly appreciated. Thanks Jesus



Tom H Members Profile Send Private Message Find Members Posts Add to Buddy List Admin Group Joined: 05 Jan 2012 Location: San Diego, CA Status: Offline Points: 5719	Post Options Post Reply Quote Tom H Report Post Thanks(1) Quote Reply Posted: 06 Nov 2015 at 10:09am
	The only option is to hand solder the component to ensure a good top fillet. The questions below can affect the ability to perform this solder joint. Also assumes properly formed replacement parts are not available. What is the application for the final assembly? Is it Class 2? 3? Is it lead or lead free? What is the board thickness? What is the component lead diameter and PCB hole diameter? Id the barrel of the hole tied to any type of a copper plane? If so, are there thermal relief pads? Is it mission critical? Is it flight equipment? Answers to these questions would influence my answer to the original question.
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Eng. Jesus Mora Members Profile Send Private Message Find Members Posts Add to Buddy List Advanced User Joined: 11 Jul 2013 Status: Offline Points: 56	Post Options Post Reply Quote Eng. Jesus Mora Report Post Thanks(1) Quote Reply Posted: 06 Nov 2015 at 4:04pm
	Hello , thanks for the reply: 1- The application for the final assembly is for image processing purposes. 2- It is class 2 3- It is lead free 4- The board is about 250 mils thick 5- Lead diameter: 1mm (in most of the cases) , hole diameter : 1.3 mm 6- In most of the cases the barrel of the hole is tied to power internal planes. 7- There are thermal relief pads 8- It is very critical for the mission. 9- It is planned to be flight equipment. I hope this helps with the answer. Thanks alot.

Tom H Members Profile Send Private Message Find Members Posts Add to Buddy List Admin Group Joined: 05 Jan 2012 Location: San Diego, CA Status: Offline Points: 5719	Post Options Post Reply Quote Tom H Report Post Thanks(0) Quote Reply Posted: 08 Nov 2015 at 2:47pm
	Intrusive soldering is one option. The second option is to mill down the PCB at these locations only. There's no easy solution.
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ernestorey Members Profile Send Private Message Find Members Posts Add to Buddy List New User Joined: 10 Apr 2014 Location: Santa Clara, CA Status: Offline Points: 10	Post Options Post Reply Quote ernestorey Report Post Thanks(1) Quote Reply Posted: 10 Nov 2015 at 11:19am
	I would suggest to socket the part using wire-wrap (0.025" square post) type sockets, those have very long tails.