Common Defects Found in Electronics Inspections

Consumer electronics are complex products with high potential for defects. Identifying these defects early is crucial. Based on our data from thousands of inspections, here are the most common defects found in consumer electronics manufacturing.

1. Soldering Defects

Poor soldering (cold solder joints, bridges, or excess solder) is a frequent cause of failure. These defects can lead to intermittent connection issues or complete product failure. High-resolution visual inspection and functional testing are required to catch these issues.

2. Cosmetic Issues (Scratches & Dents)

High-gloss plastic finishes are prone to scratching during assembly and packing. "Hairline scratches" are a common point of contention. Establishing clear limit samples for acceptable vs. unacceptable cosmetic defects is vital.

3. Battery & Power Issues

Battery safety and performance are critical. Common issues include batteries failing to hold charge, overheating during charging, or swelling. We recommend 100% charging tests for critical batches and checking battery certifications.

4. Assembly Gaps

Uneven gaps between casing parts indicate poor tooling or assembly quality. This not only looks bad but can compromise the device's dust and moisture resistance.

Prevention Strategy

To prevent these defects, implement a "during production" inspection (DUPRO) to catch issues while the product is on the assembly line, rather than waiting for the final pre-shipment inspection.