Quality is found in the design as well as the process.

Solder defects are inevitable. Reducing their risk is mandatory, especially if you’re aiming to make money as a result of operations. Machines are certainly not “almost human,” but they do go through seasonal changes and have moods. Without proper upkeep, they fall into disrepair. The goal in assembly is to dial in the thermal profile of the soldering equipment to minimize solder defects.

Footprint model accuracy is an enabler, but that work can be undone by improper routing and copper-flooding techniques. Placement too near the edge of the board where the temperature fluctuates to a greater degree can decrease yields through the soldering process. Tombstoning is one thing to watch for, but other dangers are present on the frontier.

The Goldilocks zone. Another defect can occur when one lead of a component is close to the edge while the other is farther inward. Wirewound resistors and inductors can become open circuits or more insidiously latent defects, where the wire pulls away from the lead only when there is a temperature rise or a mechanical shock to the system. Ceramic caps can actually crack when one lead solidifies before the other one.

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