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Component Leads Too Short

Printed From: PCB Libraries Forum
Category: General
Forum Name: General Discussion
Forum Description: general topics not related to other forums
URL: https://www.PCBLibraries.com/forum/forum_posts.asp?TID=1789
Printed Date: 03 Nov 2025 at 8:20pm


Topic: Component Leads Too Short
Posted By: Eng. Jesus Mora
Subject: Component Leads Too Short
Date 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


Replies:
Posted By: Tom H
Date 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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Posted By: Eng. Jesus Mora
Date 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.

Posted By: Tom H
Date 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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Posted By: ernestorey
Date 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.


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