A Glimpse into W&T's Manufacturing Process

At W&T, quality isn't just a goal; it's our foundation. As a power supply manufacturer, we know reliable performance is everything.

We're committed to delivering power supplies that stand for durability, efficiency, and unwavering performance. Our team's dedication makes us your trusted partner for reliable power solutions.

Here  we would like to introduce W&T Power adapter production process . I‘ll start with a brief overview of the manufacturing process and with more detailed description of each step in the production process. Hope you can more learn about our company. Thank you.

Here attached a production flow chart to give you a general idea of the process

IQC Raw Materials Inspection

Incoming Quality Control (IQC) is a critical step in the manufacturing process where you inspect raw materials, components, and parts from suppliers before they enter your production line. It's the first line of defense against defects and is absolutely essential for several key reasons.

SMT 

SMT (Surface Mount Technology) is a method for manufacturing electronic circuits where components are directly mounted or placed onto the surface of a PCB (Printed Circuit Board). For power supplies, SMT is not just a choice—it's a critical process that offers significant advantages over older through-hole technology.

AOI TEST

AOI (Automated Optical Inspection) is a critical step in the assembly of power supplies, using cameras to scan a PCB (Printed Circuit Board) for catastrophic failures and quality defects. It is a fundamental part of the quality assurance process, especially for high-volume production.

PCB Plug-in components  

PCB (Printed Circuit Board) plug-in components, also known as through-hole components, are parts with leads that are inserted into holes drilled in a PCB and then soldered. While modern power supplies heavily rely on SMT (Surface Mount Technology), plug-in components remain critically important for specific applications.

Automatic Wave Soldering

The wave soldering process is highly controlled. The conveyor speed, solder temperature, and flux application are all precisely managed. This level of automation eliminates human error and ensures that every single board is soldered to the same high standard. This consistency is vital for maintaining product quality and reliability across large production runs.

Repair Weilding & PCB visual inspection

After automated processes like SMT (Surface Mount Technology) and wave soldering, it's rare for every single board to be perfect. This is where Repair/Rework and PCB Visual Inspection become critically important. They are the final human-led quality checks that ensure a power supply is not only functional but also safe and reliable.

Automatic PCB Board Cleaning

The main purpose of cleaning is to remove any residue from the board's surface. These contaminants, like dust, fingerprints, or oxidation, can prevent the solder from properly wetting the copper pads. This leads to weak or "cold" solder joints, which are a major cause of failure in power supplies. A clean surface allows the solder to flow evenly, creating a strong and reliable electrical connection.

PCB FCT

PCB FCT is not just a simple check; it's a full-scale performance validation. The test system measures key electrical parameters such as output voltage accuracy, ripple and noise, over-voltage protection (OVP), over-current protection (OCP), and efficiency. It verifies that the power supply meets all its specified performance and safety requirements.

Assembly  

Assembly is the point where the PCB, which has been through SMT, wave soldering, and inspection, is integrated with all the other elements. This includes soldering plug-in components like large capacitors and transformers, installing heatsinks, putting the PCB into its casing, and connecting all the wires and connectors. The quality of these physical connections and the overall structure directly impacts the power supply's safety and long-term reliability.

Auto Burn-in test  

The automatic aging test, or burn-in test, is a crucial reliability screening process in power supply manufacturing. During this test, finished power supplies are operated under a controlled, high-stress environment for a set period. This helps to identify and eliminate products that are likely to fail early in their life cycle.

W&T carry the 100% burn-in testing at least 2 hours. 

Hi-POT test &Function Test & Automatic function test 

After assembly, power supplies must undergo rigorous final testing to ensure both safety and performance. Two of the most critical tests are Hi-Pot (High Potential) testing and ATE (Automatic Test Equipment) Functional testing. These tests are the final gatekeepers of a power supply's quality and reliability.

Electrical testing: including output voltage, current, efficiency, temperature rise and other index tests and Safety testing: insulation test, overload test, short circuit test, etc

Ultrasonic welding

Ultrasonic welding is a critical manufacturing process used to permanently join the plastic top and bottom covers of a power supply. This technique uses high-frequency vibrations to create a molecular bond between the two plastic parts, offering a superior and more reliable alternative to screws, snaps, or adhesives.

Laser Marking  

Laser marking (or laser engraving) is a process that uses a focused laser beam to create permanent markings on a product. For power supplies, this isn't just a cosmetic step; it's a critical part of product identification, safety, and branding.

Visual inspection 

Final visual inspection is the last quality control checkpoint before a power supply is packaged and shipped. It's a crucial process that relies on the human eye and touch to identify a range of cosmetic and minor functional defects that automated tests might miss. This step is essential for ensuring both customer satisfaction and brand reputation.

Checking for Internal Noise (Tapping Test) & Cable and Connector Integrity & Detecting Scratches or Cosmetic Blemishes & LED Indicator Functionality & Verifying Laser Marking Quality ect.

Packing  

Packaging is the final, critical component that protects a power supply, provides essential information, and represents a brand. A high-quality package ensures the product arrives at the customer in perfect condition.

FQC Test

Final Quality Control (FQC) is the last and most critical inspection stage before a power supply is packed and shipped. It is a comprehensive final check of the product's quality, appearance, and function to ensure it meets all specifications and is ready for the customer.

Warehouse  

Once a power supply has passed all final quality checks, including FQC (Final Quality Control), it moves to the warehouse. Storing finished power supplies on designated shelves and racks, each with an FQC PASS label, ensures the product remains in perfect condition before shipping. This system prevents products from being damaged, contaminated, or mixed up, protecting the quality that has been so carefully built in every step of the manufacturing

Shipping  

At W&T, we understand that prompt delivery is as important as product quality. We are committed to shipping on time according to our customers' specific requirements. Our organized warehousing and logistics systems are designed to ensure that as soon as an order is placed, it is processed and shipped without delay.

Our rigorous production flow is the key to our exceptional quality control. At W&T, we believe that quality is built into every step, not just tested at the end. We've established strict controls on our production lines, allowing us to maintain a defect rate of less than 0.3%.

Our mission is to become your trusted and stable power supply partner.

Our Main Products

• AC/DC Power Adapters: Reliable and efficient power solutions for a wide range of electronic devices.

• PD Chargers: High-speed, safe, and compact chargers for the latest laptops, smartphones, and tablets.

• Battery Chargers: Customized charging solutions designed to protect and optimize battery life.

• LED Drivers: Consistent and stable power to ensure the long life and performance of your LED lighting.

• Open-Frame Power Supplies: Compact and powerful solutions for integration into a variety of electronic systems.

• Custom Power Supplies: Bespoke power solutions engineered to meet your unique project requirements.