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January 20, 2026 - San Mateo, California - Since 2005, San Francisco Circuits
(SFC)
has been a trusted U.S. provider of advanced PCB manufacturing and assembly solutions
for R&D innovators, prime contractors, and integration experts. SFC
has published a white paper entitled, "PCBA Press Fit Connector Reliability: Strain Thresholds and Best Practices,"
to help inform you on issues that can mean the difference between success and
failure.
Press fit connectors are common in high-density PCB designs - powering 5G infrastructure,
electric vehicles, aerospace systems, and advanced medical devices. Their ability
to deliver high I/O counts without the heat risks of soldering makes them indispensable
for modern electronics.
But here's a hidden risk: If strain during insertion isn't properly managed,
it can lead to latent solder joint cracks, fractured plated through holes (PTHs),
or deformed pins. These failures often escape detection during testing and only
surface in the field - causing warranty returns, costly recalls, or even mission-critical
system outages.
In this post, we'll cover how stress impacts PCB reliability, safety thresholds,
and how to overcome these challenges in your application.
Understanding Press Fit Strain
 Press fit technology uses an interference fit, where connector pins are pressed
into PTHs with near-zero clearance to form a tight mechanical and electrical bond.
A controlled force (up to 600 lbs for a 60-pin connector) drives this process, causing
the PCB to flex. This flexure generates strain that can crack solder joints, PTH
barrels, or deform pins, threatening reliability in high-stakes applications like
aerospace or medical devices. For instance, a medical client could face costly MRI
control board failures due to BGA cracks near press fit sites, underscoring the
need for precise strain management.
Types of Press Fit Connectors
There are two main types of press-fit pins:
- Solid pins, which feature a rigid press-in zone.
- Compliant pins, which have an elastic press-in zone that allows for flexibility
and deformation during insertion.
Both types of press-fits can either be soldered or solderless, depending on the
application (pin count/density, risk of thermal stress during soldering, simplicity
of assembly).
Please visit
San Francisco Circuits website for ... the rest of the story!
San Francisco Circuits serves industries where performance and security converge,
including aerospace & defense, medical devices, industrial & energy, and
advanced communications. The company's technical depth spans rigid, flex, and rigid-flex
PCB fabrication, with expertise in HDI and RF/microwave designs, adhering to IPC,
MIL-SPEC, AS 9100, ISO 9001:2015, and ANSI ESD standards.
For system integrators, every connection matters - including the partner you
trust with your intellectual property and system backbone. San Francisco Circuits
delivers precision-engineered PCBs backed by industry-leading data protection and
mission-level reliability.
Read more on PCB solutions for system integrators on the San Francisco Circuits
website.
About San Francisco Circuits
San Francisco Circuits is a provider of PCB fabrication and assembly, has a dedicated
team specializing in simple and complex PCB fabrication and assembly technologies.
They can produce elaborate and high-quality PCBs in a number of custom and common
layouts. From basic to intricate PCBs–their engineers will meet your PCB fabrication &
assembly needs. The company provides a rare balance between technical expertise
and competitive pricing. And they not only provide high-quality products but also
high-quality customer service at the same time. San Francisco Circuits has been
voted by National Television as the "world's greatest in PCBs" and has demonstrated
experience as a power player in PCB fabrication and assembly.
If you are looking to discuss PCB projects of any size or scope, feel free to
reach out to them via our website (see below).
Contact
Victor Bilandzic
San Francisco Circuits, Inc.
Phone: 1-800-732-5143
Web: www.sfcircuits.com
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