Electronics manufacturing has largely shifted toward surface-mount technology (SMT) due to its cost efficiency, automation capabilities, and ability to support miniaturization. In fact, Surface-mount technology (SMT) has become the dominant method for PCB assembly, representing the vast majority of current production, particularly for high-volume applications. But does that mean through-hole PCB assembly is outdated? Not at all. In this blog, we discuss why through-hole PCB assembly manufacturers are making an impact in the industry.

Why Through-Hole PCB Assembly Manufacturers Still Matter

Through-hole PCB assembly manufacturers matter because through-hole PCB play an important role in electronics products across industries. For industries that demand durability, mechanical stability, and long-term reliability—such as automotive, aerospace, industrial, and medical electronics—through-hole technology remains essential. The mechanical strength of through-hole components, combined with modern automation techniques, ensures they continue to play a vital role in electronics manufacturing.

Built for Strength and Longevity

Through-hole assembly isn’t just about placing components on a board; it’s about how they are anchored. By inserting component leads into drilled holes and soldering them on the opposite side, this method creates a stronger mechanical bond—something SMT can’t always match.

This durability is critical for many products and environments:

  • High-vibration environments – Automotive control modules and aircraft systems can’t afford loose connections.
  • Electronics with moving parts – Industrial robots and heavy machinery require components that won’t break under stress.
  • Long product lifecycles – Medical devices and aerospace electronics often operate for decades, demanding long-term reliability.

Power Handling and High-Voltage Applications

Some applications require more than just a strong connection—they need to handle high power or voltage without failing. This makes through-hole technology the desired choice for a number of products:

  • Power supplies and converters – These components must carry high current safely, and through-hole designs ensure stable electrical connections.
  • High-voltage circuits – Increased spacing between leads helps prevent short circuits, reducing the risk of failure.
  • Transformers, relays, and connectors – These components generate heat and require solder joints that won’t degrade over time.

Because through-hole assembly embeds components deeper into the board, it also improves heat dissipation. That’s why industries like telecom, industrial automation, and power management rely on it to prevent overheating and extend product life.

Designed for Harsh Environments

Not every circuit board sits safely inside a climate-controlled environment. Many operate in extreme temperatures, high humidity, or dusty conditions. Through-hole PCBs often offer advantages in specific harsh environments, particularly those involving significant mechanical stress, vibration, or extreme temperatures. While SMT components can be made more robust, through-hole’s inherent mechanical strength makes it a preferred choice in these demanding applications:

  • Military and aerospace electronics – High altitudes and extreme thermal fluctuations demand robust connections.
  • Outdoor automation systems – Industrial controls, wind turbines, and energy grids face constant exposure to dust, moisture, and UV radiation.
  • Medical and safety-critical devices – When failure isn’t an option, through-hole designs ensure long-term performance.

Through-hole components are soldered on the opposite side of the board from where they are inserted, creating a strong mechanical connection due to the leads passing through the board. This differs from SMT components, which are soldered directly to the board surface, making through-hole connections generally more resistant to mechanical stress and vibration.

Through-Hole Assembly Is More Automated Than Ever

While through-hole assembly has traditionally been more labor-intensive than SMT, advances in automation have significantly improved its efficiency and scalability.  For example, axial insertion machines automate the insertion of axial lead components (e.g., resistors, diodes) into PCBs. They ensure precise placement and secure attachment, significantly speeding up the assembly process. Likewise, SIP (Single In-line Package) insertion machines automate the placement of SIP components. Automated soldering systems, along with these and other automated systems, enhance the efficiency, accuracy, and reliability of through-hole PCB assembly, making them essential in modern electronics manufacturing.

Through-Hole and Surface-Mount Hybrids

Rather than being competitors, through-hole and surface-mount technologies complement each other. Many modern assemblies use a hybrid approach, leveraging SMT for compact, high-density circuits while relying on through-hole for structural integrity and power-handling components.

For manufacturers producing LED assemblies, industrial control systems, and automotive electronics, a combination of both methods ensures an optimal balance of performance, cost, and reliability.

Partnering with an Experienced Through-Hole PCB Assembly Manufacturer

For companies seeking a reliable PCB assembly partner, Siemens Manufacturing has been at the forefront of high-reliability electronics manufacturing since 1963. With three manufacturing locations, ISO 9001:2015 certification, efficient electronic assembly, advanced technical skills, innovative solutions, and customer-centric service, we have the capacity and expertise to meet the most demanding requirements.

If you require durable, high-performance PCB assemblies, contact us today to learn more about our through-hole and mixed-technology PCB assembly services and learn how we can meet your needs.