Custom Reflow and Wave Pallets

For this custom 450 mm Wave Surfer build, the customer needed a wider version of our standard model that could ride lower in the wave solder machine while still retaining the same thermocouple attachment points used on the stock configuration. Since the previous design files were missing, I had to rebuild the model from scratch using the stock Wave Surfer as the design reference.

The part also required additional manufacturing consideration because the material is difficult to CNC machine efficiently. I coordinated with our manufacturing team to review the design, simplify the machining approach, and determine the most cost-effective tool paths for production. The final configuration maintained the familiar thermocouple mounting locations while extending the platform to 450 mm and lowering the ride height to better match the customer’s wave solder process.

For this custom adjustable pallet, the customer needed a fixture that could carry our 24ch thermal shield through a wave soldering machine while adapting to different conveyor track widths. I designed the pallet with adjustable side arms that can move in or out, allowing the same assembly to be configured for multiple machine setups without requiring a dedicated fixed-width carrier.

The design was also created to stay consistent with our legacy carrier products, making it familiar for customers and easier to integrate into existing wave solder workflows. I kept the construction straightforward so our production team could manufacture and assemble the pallet efficiently, while still providing the adjustability and support needed for the larger 24ch shield.

For this custom 275 mm KIC SRA build, I received a unique set of customer requirements and had to work from an older STEP file as the starting reference. Since the existing model did not fully represent the needed configuration, I used it as a baseline while adapting the design around the custom instructions. I also incorporated production feedback by modifying areas where the team had reported clearance and assembly issues, helping improve both fitment and manufacturability for the final build.