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www.us-tech.com


August 2025 ElEctronic Mfg SErvicES


Robotas Offers Solution to Aging Axial, Radial, and DIP Insertion Machines


By Georgina Blackwell, Product Design and Marketing Engineer, Robotas Technologies F


or decades, automated axi- al, radial, and dual in-line package (DIP) insertion


machines have been a staple in electronics manufacturing, effec- tively streamlining the through- hole technology (THT) assembly process. These machines provide fast turnaround times and high precision, making them invalu- able for large-scale production. However, as these systems


age, manufacturers increasingly face significant challenges in keeping them operational. High maintenance costs, difficulty in sourcing spare parts, and the im- practicality of running these ma- chines for small production runs have led numerous facilities to reduce their use of them or even abandon them completely.


Aging Machines Robotas’ Mascot systems


present a highly effective, cost-


efficient alternative to aging axi- al, radial, and DIP insertion ma- chines. By offering a stream-


justify the expense of replacing outdated equipment with new, fully automated systems. These limitations have


forced companies to either scale back their THT production or seek alternative solutions that provide the same quality and ef- ficiency without the financial strain.


An Alternative For manufacturers looking to


Mascot Clinch Conveyor THT assembly station.


lined, semiautomated approach that delivers the same precision and reliability as traditional in- sertion equipment — at a frac- tion of the cost — Robotas pro- vides manufacturers with a vi- able solution to sustain their THT operations. Many electronics manufac-


turers still rely on their aging ax- ial, radial, and DIP insertion ma- chines, but maintaining these systems has become increasingly difficult. Key challenges include:


l Obsolete and Expensive Spare Parts: With original manufactur- ers discontinuing support for old- er models, spare parts have be- come scarce and costly. Sourcing necessary components often leads to extended downtimes and operational inefficiencies.


l High Maintenance Demands: Keeping aging equipment opera- tional requires frequent servic- ing, calibration, and trou- bleshooting. Many companies find that their insertion ma- chines are only operational inter- mittently, due to these mainte- nance demands.


l Limited Justification for High Investment Costs: While high- volume manufacturers may still benefit from traditional insertion machines, companies with lower production volumes struggle to


maintain high-quality THT as- sembly without the excessive costs associated with aging inser- tion machines, Robotas’ Mascot systems provide an ideal and up to date alternative. Designed to optimize manual and semiauto- mated insertion processes, Mascot Systems offer a lower investment cost while ensuring precision, reli- ability, and ease of use. Robotas’ Mascot Clinch Con-


veyor streamlines the THT as- sembly of PCBs using an electro- static discharge (ESD)-safe, SMEMA-controlled motorized conveyor. The integrated clinch technology allows component leads to be bent in any direction (360°) and at various angles


While automated


insertion machines are known for their precision and speed, their high investment costs, long set up times, and mainte- nance challenges make them impractical for many manufacturers.


(from 35° to 85°), ensuring se- cure placement and preventing component dislodgment during the wave soldering process. Robotas’ carousels and dy-


namic pick-to-light arrays auto- matically present required com- ponents to the operator at every step of the assembly process. The Mascot software and laser guides operators on polarity and place- ment, reducing errors and im- proving efficiency. Traditional axial and radial


insertion machines require ex- tensive setup for each PCB as-


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