1. Background Overview

A European client specializing in industrial automation sought a reliable and high-precision PCBA partner for their mass flow meter product. They needed a solution to improve measurement accuracy, ensure high durability under harsh industrial environments, and maintain competitive cost efficiency.

2. Application Scenario

The mass flow meter is widely used in semiconductor manufacturing, chemical processing, and industrial gas flow monitoring. It requires PCBA assemblies with excellent precision, anti-corrosion capabilities, and long-term operational stability.

3. Product Specifications

Parameter	Specification
Flow Measurement Range	5 SCCM to 300 SLPM
Accuracy	±1.0% of reading
Repeatability	±0.2% of reading
Response Time	≤ 1 second
Operating Temperature	0°C to 50°C
Output Signal	0-5V, 4-20mA, RS485
Power Supply	15-24V DC
Materials in Contact with Gas	Stainless Steel, Aluminum Alloy

4. Application Results

• Quality improvement: Enhanced PCB layout and precise assembly reduced signal noise by 15%, boosting measurement accuracy.
• Cost optimization: Improved design for manufacturability (DFM) practices led to a 7% reduction in production costs.
• Performance upgrade: Thermal management enhancements extended product service life by 10%.
• Delivery efficiency: Streamlined PCBA production process shortened lead time by 12%.

5. KKPCB’s Advantages Demonstrated in This Case

KKPCB leveraged its strengths in precision PCB manufacturing and high-reliability PCBA assembly to meet the client’s stringent requirements. We utilized advanced AOI, SPI, and X-ray inspection systems to ensure defect-free production. Our IPC-A-610 Class 2/3 compliance and ISO9001-certified processes guaranteed consistent quality. KKPCB’s flexible production capacity also allowed for rapid prototype to mass production transition, helping the client scale efficiently.

6. KKPCB’s Customized Manufacturing Solutions

For this project, KKPCB provided full-stack support focused on:

• PCB manufacturing optimization: Using low-loss materials and precision impedance control to improve signal integrity.
• PCBA process improvement: Implementing selective conformal coating to protect critical areas without compromising sensor sensitivity.
• Assembly enhancements: Fine-tuning soldering profiles for mixed SMT/THT components, ensuring high mechanical strength and electrical reliability.
• Reliability testing: Conducting high/low temperature cycling and vibration testing to validate assembly robustness. Through these manufacturing-focused optimizations, KKPCB delivered a robust, cost-effective, and performance-enhanced PCBA solution tailored to the European industrial market.

7. Actual Results of the Solution

Thanks to KKPCB’s professional manufacturing solutions, the client’s final mass flow meter achieved:

• Precision boost: Calibration yield improved by 10% during final product testing.
• Cost savings: Assembly and testing cost per unit decreased by 6.5%.
• Performance reliability: Field failure rate reduced to less than 0.1% over 12 months.
• Faster time-to-market: Total project delivery time was accelerated by 15%, supporting faster market entry.