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SEPTEMBER 2025 I SMT007 MAGAZINE 43 • Inline placement: Many systems are designed to slot directly into production lines, positioned before selective soldering to minimize handling of the assembly • Space reduction: Systems are compact and can eliminate space-consuming slide lines and manual workstations The ROI extends beyond labor savings. Reduced rework, improved quality, and the ability to accept more complex customer assemblies all factor into ROI. When Odd-form Automation Doesn't Make Sense While the benefits of dedicated odd-form equipment are substantial, they're not universal. In certain cases, the return on investment can be harder to justify. Typically, high-mix, low-volume production environ- ments have a harder time justifying odd-form auto- mation. When dealing with a high array of odd-form components without substantial volume, the cost of custom feeders and nozzles can outweigh the efficiency gain and labor reallocation. Of course, there are exceptions, but if an odd-form component appears only occasionally in a product portfolio, the expense of automating is usually not practical. In these situations, manual or semi-automated solutions may be more cost-effective, even if they lack the throughput and consistency of full automation. Best Candidates for Automation As noted above, not every component on a board is worth automating. Ideal candidates include: • High-volume, repetitive builds: Sustained production volumes make investments in custom tooling easier to justify S M A RT AU TO M AT I O N • Physically demanding insertions: Parts requiring significant force to seat can cause operator fatigue and potential product damage, making them better suited for automation • Components with high defect rates: Parts that cause expensive rework or scrap when placed improperly are ideal candidates • Multi-lead, orientation-critical parts: Compo- nents that require tight rotational accuracy or complex lead alignment benefit from vision or laser-assisted placement By focusing automation efforts on these sweet- spot components, manufacturers can maximize ROI while keeping equipment usage high. Conclusion: Odd-form Automation as a Strategic Capability The capital investment required for dedicated odd- form placement technology is substantial, making careful application review essential. When applied to continuous high-volume production or components whose quality directly influences overall product performance, the return on investment can be rapid. In an era where speed and miniaturization dominate marketing, the ability to automate and place large, irregular, and mechanically critical components can become a key differentiator. SMT007 Josh Casper is a regional sales manager for Horizon Sales. To read past columns, click here.