Neglecting the microclimate can lead to a range of issues that aren’t always immediately apparent and often surface only after the device has been in use for some time. Excess humidity in the air causes electronic components – especially those in plastic packages – to absorb moisture like a sponge. As a result, during the high-temperature soldering process, the water trapped inside the component rapidly turns into steam, creating sudden pressure buildup and internal stress. This phenomenon, known as the popcorn effect, can lead to microcracks inside the package, damage to the semiconductor structure, and in extreme cases – complete component failure during testing or actual usage.
On the other hand, overly dry air presents a silent threat in the form of electrostatic discharge (ESD). In low humidity environments, electrostatic charges build up much more easily – all it takes is a technician’s movement, contact with an ungrounded tool, or even simply wiping a surface. These discharges are invisible to the human eye, but for sensitive integrated circuits, they can be fatal – damaging insulation layers, transistor gates, or causing subtle defects that manifest only after hundreds of hours of device operation.
But that’s not all. Ambient conditions also have a significant impact on the soldering process, which is a critical stage in connecting components to the PCB. An overly dry or humid microclimate can accelerate the oxidation of solder alloys – especially those containing tin. Metal oxides that form on the surface of the solder interfere with proper bond formation, resulting in cold joints, unstable contacts, and potential failure points. The result? A circuit that passes initial tests may fail during its first intensive use.
That’s why when choosing a contract electronics manufacturer, it’s worth asking one very specific question: How do you manage your production environment? The answer can have a massive impact on the final result. Here’s why:
Lower risk of returns and complaints – well-controlled conditions minimize hidden defects that might only show up at the end-user stage.
Greater product reliability – a stable production environment means consistent quality and long-term durability of the final product.
Professionalism in every detail – if a company takes microclimate control seriously, it likely applies the same level of care throughout the entire production process.
At Elhurt EMS, we leave nothing to chance. As an experienced partner in electronic manufacturing services, we provide our clients not only with high-quality assembly but also with full control over production floor conditions. Our assembly lines operate in a carefully controlled environment – with precise temperature and humidity regulation, complete ESD protection, and constant monitoring. Because we know that quality starts with the things that… aren’t visible at first glance.