Industrial Humidity & Temperature Sensor PCBA Solution Case Study
1. Background Overview
A European client in the industrial automation sector required a compact, highly accurate humidity and temperature sensor solution with stable performance under harsh environmental conditions. To meet this demand, KKPCB was entrusted with providing a reliable, cost-efficient, and fast-delivery PCBA manufacturing solution for this sensor project.
2. Application Scenario
The humidity and temperature sensor is integrated into industrial HVAC systems, climate monitoring in production lines, and smart environmental control systems. It is essential in precision manufacturing processes where ambient condition stability is critical for product quality and energy efficiency.
3. Key Product Specifications
| Parameter | Value |
|---|---|
| Sensing Type | Capacitive for humidity, band gap for temperature |
| Humidity Accuracy | ±1.7% RH (10–90% RH) |
| Temperature Accuracy | ±0.2°C |
| Operating Voltage | 3.0V to 5.5V |
| Output Type | I²C Digital Output |
| Operating Temperature Range | -40°C to +125°C |
| Response Time (Humidity) | ≤ 5s |
| Board Size Requirement | ≤ 30mm x 30mm |
4. Application Results
- Quality Improvement: Enhanced signal integrity through optimized PCB layout, reducing sensor drift and noise by 63%.
- Cost Reduction: Streamlined assembly and reduced BOM complexity led to an 8.2% decrease in total unit cost.
- Performance Upgrade: Improved thermal dissipation and trace shielding improved stability in fluctuating environments by 47%.
- Lead Time Optimization: Total PCBA delivery cycle was reduced from 4 weeks to 2.3 weeks, accelerating the client’s product launch.
5. KKPCB Advantages Demonstrated in This Project
KKPCB leveraged its end-to-end capabilities from multilayer PCB fabrication to high-precision PCBA assembly to deliver a stable and miniaturized sensor solution. Through rigorous DFM checks, X-ray inspection, AOI, and customized functional testing, we ensured zero-defect delivery. Our proactive engineering support and flexible production scheduling helped the client overcome prototyping challenges and meet aggressive go-to-market timelines.
6. KKPCB’s Custom Manufacturing-Focused Solution
Understanding the client’s need for ultra-compact and high-accuracy PCBA, KKPCB proposed a 4-layer PCB stack-up with tight impedance control and moisture-resistant board finish. We applied selective conformal coating to protect key sensing components from condensation without interfering with sensor accuracy. Components were placed with a ±20μm accuracy using our SMT line, ensuring optimal performance in extreme conditions.
We also offered value-added engineering support, such as component substitution proposals during material shortages, and delivered complete traceability documentation in line with European regulatory compliance.
7. Real-World Impact of the Solution
Thanks to KKPCB’s tailored manufacturing approach, the client reported:
- Zero field failures during the first six months of deployment
- A 14% improvement in environmental data accuracy under high-humidity conditions
- A 10% decrease in system-level energy consumption due to faster, more stable sensor feedback
- A 2-month earlier market entry than originally scheduled
