Robotas Technologies Drives Innovation in Through-Hole Assembly Amid an SMT-Dominated Landscape
By Georgina Blackwell
As the electronics industry continues to evolve at a remarkable pace, the spotlight often falls on Surface Mount Technology (SMT) as the dominant method of assembly for modern printed circuit boards (PCBs). With its high-speed capabilities, compact design, and automation potential, SMT has become synonymous with advanced electronic manufacturing. However, in this age of miniaturization and rapid SMT innovation, Through-Hole Technology (THT) remains a vital and irreplaceable process across numerous industry sectors. Robotas Technologies stands as a steadfast advocate for the continued advancement of THT assembly, offering purpose-built solutions that address today’s manufacturing needs with precision, reliability, and efficiency.
The Enduring Value of Through-Hole Assembly
Though often overshadowed by SMT, THT assembly retains a stronghold in sectors requiring high mechanical strength, durability, and component security. Applications involving high-power or high-voltage components such as those in industrial controls, aerospace, defense, and power electronics still rely heavily on through-hole components. These parts are typically larger and heavier, benefitting from the added strength of soldered leads that pass through the board.
THT also offers significant advantages in prototyping and low- to medium-volume production. Unlike SMT, which often requires substantial investment in automated placement equipment and reflow ovens, THT can be implemented with comparatively lower capital expenditure. This makes it an ideal choice for companies developing custom, small-batch, or experimental electronics products.
Despite these benefits, the industry trend has been shifting away from THT. Many equipment manufacturers have stopped producing dedicated THT assembly systems, preferring SMT-oriented innovation. This transition creates a critical gap in the market, where demand for THT workstations continues, but supply has diminished.
Robotas Technologies Fills the Void
Robotas Technologies has remained committed to THT assembly solutions, maintaining and expanding its portfolio of intelligent workstations that enhance manual assembly accuracy and productivity. Founded in 1985 by Dave Walters, Robotas was established with a clear vision: to create a simple, affordable system that guides operators in the accurate placement of components on circuit boards.
The company’s flagship solution, the Mascot System, emerged as a cornerstone of THT production during an era when hand assembly was integral to electronics manufacturing. At a time when competitors like Contact Systems and Royonics also supported the market, Robotas distinguished itself with user-friendly technology designed to ensure precision and repeatability.
As industry focus shifted toward SMT, many THT equipment manufacturers exited the space, leaving legacy systems unsupported and spare parts increasingly difficult to source. This has created challenges for manufacturers that still rely on aging systems like Contact Systems’ CS-400 or the Royonics machines. For these users, maintaining outdated machinery has become costly and unsustainable.
Robotas provide a lifeline to these operations. The Mascot System delivers all the core features of its now-obsolete predecessors while also offering compatibility with existing CAD data and a host of advanced capabilities designed for today’s production challenges.
Intelligent Features for Modern THT Assembly
Robotas’ Mascot System includes dynamic pick-to-light arrays and carousels that streamline the component selection process, minimizing handling errors and improving ergonomic access for operators. A guided laser head precisely indicates the correct placement location on the PCB, with polarity indicators integrated both in software and through laser visualization to eliminate costly orientation mistakes.
Programming the system is intuitive and compatible with CAD data from Contact Systems and Royonics machines, facilitating a seamless transition for customers upgrading from legacy equipment. Available as a standalone workstation or integrated into an in-line configuration using SMEMA-compatible conveyors or push-track systems, the Mascot platform can be tailored to suit diverse production environments.
Robotas continues to invest heavily in R&D, regularly enhancing its solutions with new modules and capabilities. A prime example is the introduction of its proprietary Clinch Technology, which enables component leads to be securely clinched during manual placement. This feature improves mechanical retention and reduces soldering errors downstream.
Closing the Loop on Quality Control
In response to the growing demand for quality assurance in manual processes, Robotas launched VERIFY, a real-time inspection verification module that integrates seamlessly into the Mascot System. VERIFY ensures every component is accurately placed before soldering, helping manufacturers eliminate defects at the source rather than relying on post-process inspection or rework.
The system inspects for the presence and absence of components, as well as orientation and polarity errors. By verifying placement before solder, VERIFY supports a “no faults forward” approach, significantly improving first-pass yield and reducing production delays. This is especially beneficial in high-reliability industries where the cost of failure is high.
A Strategic Commitment to THT
While many in the industry have shifted their resources away from THT in favor of SMT, Robotas Technologies remains one of the few companies actively innovating in this critical space. Its continued development of new tools, features, and modules reinforces the company’s commitment to serving manufacturers who rely on through-hole technology.
Robotas’ mission is not simply to maintain legacy systems, but to enhance and future-proof THT assembly for a new generation of electronics manufacturing. By combining the familiarity and reliability of traditional THT processes with intelligent automation and real-time verification, Robotas is helping its customers bridge the gap between past and future.
Conclusion
THT assembly is far from obsolete; it remains an indispensable part of the electronics manufacturing ecosystem. For companies that depend on the mechanical robustness and reliability of through-hole components, Robotas Technologies provides the tools and support they need to excel. With the Mascot System and VERIFY module, Robotas continues to deliver cutting-edge solutions that improve accuracy, reduce waste, and maximize efficiency.
As the only manufacturer still deeply invested in dedicated THT workstations, Robotas fills a crucial void in the market. The company’s commitment to innovation ensures that through-hole assembly can evolve alongside SMT – not in its shadow, but as a complementary force in a diversified production strategy.
For more information about Robotas Technologies Ltd., contact Georgina Blackwell, Product Design & Marketing Engineer, at Unit 4 Thirkill Park, Thirkill Drive, Pannal, Harrogate, HG3 1GQ. UK; +44 (0) 1474 815 815; E-mail: sales@robotas.com – Web site: www.robotas.com.
