Understanding Class 1, 2, and 3 Electronics Assemblies

Not all electronic assemblies are created equal, and that’s by design because the expectations for a consumer gadget versus a mission-critical medical device couldn’t be more different. Every device has a purpose, and the environment in which it operates directly impacts how reliably that device must function. Enter the IPC classification system: a universal standard that segments electronic assemblies into Class 1, Class 2, and Class 3.

At August Electronics, we work closely with OEMs across North America to ensure their products meet the right standards because understanding IPC class requirements isn’t just a technical detail, it’s foundational to long-term success. Whether we’re building rugged aerospace controls or reliable consumer tech, we help our client-partners navigate classifications with clarity, precision, and purpose.

What Are Electronics Assemblies?

Electronic assemblies are the functional cores of modern technology. At their simplest, they are collections of interconnected components—resistors, capacitors, microprocessors—soldered to a printed circuit board (PCB). But they are also more than that. Each assembly is the sum of complex manufacturing techniques, quality assurance protocols, and design intentions.

Assemblies can be:

• Through-hole or surface mount
• Single-layer or multi-layer
• Rigid, flex, or rigid-flex
• Built for analog, digital, or RF applications

Depending on their class, each of these assemblies must meet specific tolerances, solder joint requirements, and aesthetic standards.

Why Classification Matters in Manufacturing

Classification is not simply about quality—it’s about fit-for-purpose design. A medical defibrillator and a wireless doorbell cannot, and should not, be built to the same standards. This isn’t just cost optimization. It’s about ensuring reliability where it counts and reducing overengineering where it doesn’t.

Benefits of IPC Classification:

• Predictability: Set clear expectations from the start
• Design Alignment: Tailor designs to performance needs
• Cost Efficiency: Avoid over-specifying
• Regulatory Compliance: Meet industry-specific certifications

At August Electronics, these classifications guide every project from quoting through prototyping to volume production.

IPC Standards Overview: The Backbone of Quality

The IPC-A-610 standard, developed by the Association Connecting Electronics Industries (IPC), is the industry-recognized benchmark for the visual acceptability of electronic assemblies. It defines criteria for the workmanship quality of PCB assemblies, focusing on visual inspection guidelines across various product classes.
The latest revision (IPC-A-610H) refines criteria across these classes:

• Class 1: Acceptable quality for basic functionality
• Class 2: Moderate inspection and extended performance
• Class 3: Stringent requirements for critical reliability

Other relevant IPC standards:

• IPC-A-600: Acceptability of PCBs
• IPC-6012: Qualification and performance for rigid PCBs
• IPC-J-STD-001: Requirements for Soldered Electrical and Electronic Assemblies
• IPC-2221: Generic Standard on Printed Board Design

At August Electronics, our IPC-certified trainers and inspectors maintain strict adherence to evolving IPC standards through structured internal audits and scheduled recertification. We conduct comprehensive IPC training every three years across our production teams to ensure consistent application of workmanship criteria. This process supports reliable compliance with Class 2 and Class 3 requirements and reinforces our commitment to repeatable, standards-driven quality.

Class 1 Assemblies: Low-Risk Applications

What Are Class 1 Assemblies?

Class 1 assemblies are built for general electronic products where extended life or cosmetic perfection is not required. These are typically inexpensive, mass-produced, and meant for low-risk environments.

Examples Include:

• Calculators
• Toys and hobby kits
• Flashlights
• Entry-level audio/video devices
• Basic remote controls

Functional Priorities:

• Basic connectivity
• Minimum functionality
• Visual imperfections tolerated if functionally acceptable

Manufacturing Traits:

• Simplified inspection
• High-volume, cost-driven
• Greater tolerance for misalignments or flux residues

Why Choose Class 1?

Choosing Class 1 allows OEMs to lower cost barriers without compromising end-user satisfaction—when expectations are clearly defined.

Class 2 Assemblies: Workhorse of the Industry

Defining Class 2 Assemblies

Class 2 electronics strike a balance between functionality and affordability. These products must operate reliably over their intended lifespan but are not usually life-threatening or safety-critical if they fail.

Typical Applications:

• Automotive infotainment and control modules
• Smart home devices
• Point-of-Sale systems
• Industrial automation panels
• Medical diagnostic devices (non-life supporting)

Performance Focus:

• Sustained function over time
• Cosmetic defects allowed within limits
• Intermittent performance issues are not acceptable

Manufacturing Considerations:

• Moderate inspection requirements (AOI, visual, X-ray)
• Consistency and yield optimization are crucial
• Some manual touch-up may be involved

At August Electronics, Class 2 assemblies account for a substantial share of our output, particularly in industrial automation and automotive electronics. We manufacture in alignment with IPC-A-610 Class 2 standards and support compliance with regulatory and certification requirements such as Intertek ETL, CSA Group and UL. 

Class 3 Assemblies: When Failure is Not an Option

Class 3 Explained

This is the pinnacle of electronic assembly quality. Class 3 assemblies are used where failure could cause catastrophic loss—of life, property, or mission. In these assemblies, precision isn’t an advantage. It’s a requirement.

Mission-Critical Examples:

• Aerospace avionics and satellite communications
• Pacemakers, insulin pumps, and surgical tools
• Military navigation systems and weapons controls
• Railway signaling electronics

What Sets It Apart:

• Tighter workmanship tolerances and inspection criteria
• Under magnification inspections of every solder joint
• X-ray inspection of BGA components is standard
• Conformal coating and underfill often required
• Documented flow of every component and operator action

August Electronics supports Class 3 production with a dedicated team of IPC-A-610 Class 3-certified personnel, operating within an ISO 9001:2015 and ISO 13485:2016 certified quality management system to ensure reliability beyond specification.

Class 1 vs Class 2 vs Class 3: A Side-by-Side Comparison

Choosing the right assembly class is not just a technical decision, it’s also a strategic business decision. It impacts product design, testing procedures, cost, time to market, and customer satisfaction. Below is a deeper comparison based on real manufacturing outcomes.

Comparison Table: Key Attributes by Class

Attribute	Class 1	Class 2	Class 3
Functionality	Basic operation	Continuous and reliable functionality	Uninterrupted, high-reliability performance
Product Lifecycle	Short-term or single-use	Moderate lifecycle (2–5 years)	Extended lifecycle (10–20+ years)
Defect Tolerance	High	Moderate	Extremely low to none
Inspection Level	Minimal visual inspection	Automated Optical Inspection (AOI)	AOI + X-ray + manual under magnification
Assembly Cost	Lowest	Moderate	Highest
Solder Joint Criteria	Satisfactory for function	Smooth and solid joints required	Flawless solder joints mandatory
Cleanliness	Not critical	Limited contamination acceptable	Near-zero contamination required
Operator Skill	Basic training	Skilled and certified	IPC-A-610 Class 3 certified + audits

At August, we’ve found that collaborating with customers on this matrix early in the New Product Introduction (NPI) process significantly reduces the risk of costly redesigns later in the product lifecycle. For both Class 2 and Class 3 assemblies, we maintain consistent inspection checkpoints—including AOI, X-ray, and manual inspection under magnification—ensuring elevated quality standards are met regardless of classification. This approach provides added assurance, especially for clients operating in regulated or reliability-critical sectors.

Box Build Assembly: The Final Frontier of Electronic Integration

When discussing Class 1, 2, and 3 assemblies, it’s essential to recognize that many electronics projects go beyond the circuit board alone. This is where box build assembly—also known as mechanical system integration—enters the equation. At August Electronics, box build services complete the journey from PCB assembly to a fully functional, ready-to-ship product.

What Is Box Build Assembly?

Box build assembly refers to the entire electromechanical system enclosure process. It includes integrating assembled PCBs into casings, wiring harnesses, power supplies, displays, and other modules. These assemblies are then tested as a complete unit for functionality, safety, and performance.

Box Build Capabilities at August Electronics:

• System-level assembly for Class 1, 2, and 3 products
• Cable routing, wire harnessing, and mechanical integration
• Final packaging, labelling, and logistics support
• Full functional testing at the unit and subsystem level

Why It Matters by IPC Class:

IPC Class	Box Build Considerations
Class 1	Basic enclosure fitment, minimal cable routing, quick-turn builds
Class 2	Balanced approach with moderate complexity in mechanical and wiring layouts
Class 3	High-precision integration, documentation traceability, EMI shielding, ruggedization

Seamless Assembly from PCB to Product

August Electronics ensures the box build process aligns with the intended IPC classification. This holistic approach minimizes handoffs, streamlines quality control, and reduces time to market. For Class 3 projects, our clean, ESD-controlled environments and cross-functional QA checkpoints ensure your mission-critical device remains reliable—even after it’s encased.

From Boards to Boxes, We’ve Got You Covered

Whether you’re producing a Class 1 gadget or a Class 3 surgical system, August Electronics provides end-to-end manufacturing—from surface mount to final enclosure. This vertical integration not only enhances quality and accountability but ensures your product is ready for deployment with minimal friction and maximum control.

Key Materials Used Across Classes

Each class calls for different levels of material quality and traceability. Selecting the correct substrate, solder alloy, and surface finish based on the class of assembly is essential for performance and cost control.

Common Materials and Their Applications:

Substrates:

• Class 1: FR4 (basic grade)
• Class 2: Mid-grade FR4, polyimide
• Class 3: High-Tg FR4, Rogers laminates, ceramic substrates

Surface Finish:

• Class 1: HASL (Hot Air Solder Leveling)
• Class 2: ENIG (Electroless Nickel Immersion Gold)
• Class 3: ENEPIG, Immersion Silver, Hard Gold (for harsh environments)

Solder Alloy:

• Class 1: Sn63/Pb37 or basic lead-free
• Class 2: SAC305 or Sn100C (RoHS compliant)
• Class 3: Low-voiding high-reliability alloys, often leaded (military/medical exemptions)

Materials for Class 3 must meet tight tolerances, thermal stability, and outgassing limitations, especially for aerospace and medical applications.

Inspection and Testing Standards Across Classes

Testing is where IPC classification differences are most evident. At August Electronics, we calibrate our inspection and testing protocols to each product’s class and criticality—ensuring compliance without unnecessary over-inspection or added cost.

Industry Standard Inspection Approaches:

Inspection Method	Class 1	Class 2	Class 3
Visual Inspection	Basic only	IPC-A-610 compliant	IPC-A-610 + 10x magnification
AOI	Not required	Common practice	Mandatory
X-Ray	Not required	For BGAs only	All hidden joints and vias
ICT (In-Circuit Test)	Rarely used	Recommended	Required for fault isolation
Functional Testing	Optional	Standard	Must meet exact performance specs
Burn-in / Stress Testing	Not applicable	Sometimes used	Common in aerospace/defense

Every inspection method comes with cost considerations but at August, we take a strategic and value-driven approach to testing. While we always align with our client-partners’ expectations, we also uphold our own rigorous internal standards. With in-line solder paste inspection and in-line AOI integrated into our process, most of our boards receive enhanced scrutiny—without any added cost.

How Class Affects Assembly Time and Cost

Manufacturing high-quality electronics is a trade-off between speed, cost, and reliability. As classification increases:

• Cycle times lengthen
• Rework must be minimized
• Documentation increases

Cost Breakdown:

• Class 1: Economy-driven. Focus on throughput.
• Class 2: Balanced. Includes QA checkpoints.
• Class 3: Precision-driven. Includes serialized tracking, batch testing, clean handling.

For startups and prototyping, it’s common to begin with Class 2 requirements and transition to Class 3 as the design matures. August Electronics provides the guidance and support needed to navigate this progression efficiently.

Regulatory Environment in Canada

Canada has stringent standards that often align with or exceed IPC guidelines. Contract manufacturers must also align with:

• CSA Group standards
• UL certification (UL 796, UL 94)
• ISO 9001, ISO 13485
• Controlled Goods Program (CGP) for defense

At August Electronics, we help clients navigate Canadian and U.S. compliance frameworks, ensuring your products are export-ready and audit-compliant.

August Electronics’ Approach to IPC Compliance

We believe compliance isn’t a checkbox—it’s a philosophy. Our facility in Calgary is built around lean manufacturing principles and build-specific workflows.

What Sets Us Apart:

• IPC Trainers On-Site: Staff certified to the latest revision of IPC-A-610.
• Flexible Manufacturing Cells: Adaptable for Class 1, 2, or 3 in the same facility.
• Closed-Loop QA Systems: Data from testing feeds back into process improvement.
• Customer Audits Welcome: Transparency breeds trust.

From design for manufacturing feedback to first-build inspection reports, we align our processes to your specifications and class requirements.

Certifications and Auditor Expectations

As a contract manufacturer for regulated sectors, we maintain:

• ISO 9001:2015 – Quality Management Systems
• ISO 13485:2016 – Medical Device Quality Management
• IPC-A-610 Class 3 – Acceptability of Electronic Assemblies

We are also regularly audited for compliance with customer-maintained certifications, including:

• CSA/UL Certification – Safety compliance for electrical products
• Intertek, TÜV SÜD, and SGS – Third-party testing and certification partners
• ATEX / IECEx QAN & QAR – Quality assurance for hazardous environment applications

Typical auditor expectations include:

• Traceable batch documentation – Complete records linking components, operators, and process steps
• Operator training and certification records – Documentation of qualifications for personnel handling critical operations
• Calibration logs for test and inspection equipment – Up-to-date records ensuring measurement accuracy
• Documented rework and repair protocols – Controlled processes for identifying, addressing, and tracking non-conformances
• ESD controls and monitoring – Verified procedures and logs for electrostatic discharge protection
• Solder paste lot tracking – Lot-level traceability for consumables impacting solder joint integrity

We understand that Class 3 especially demands a culture of quality—not just procedure. And we’ve built that into our DNA at all classes.

How to Choose the Right Class for Your Product

Not sure which IPC class your product requires? You’re not alone. Start-ups and even seasoned teams can find it challenging to match product functionality with the appropriate class. That’s where a trusted manufacturing partner makes all the difference.

At August Electronics, we work closely with our client-partners from day one to navigate the classification process together—ensuring each product is built with the right level of precision, reliability, and testing to match its intended purpose.

Key Questions to Ask:

• Will the product be exposed to harsh or hazardous conditions?
• What happens if the product fails during normal use?
• Is the product life-critical, safety-critical, or mission-critical?
• What are the regulatory and legal liabilities in your market?
• Is your product’s lifecycle short (months), medium (years), or long (decades)?

Our Recommendation Framework:

Product Type	Recommended Class	Justification
Disposable consumer gadget	Class 1	Low-cost, high-volume, minimal risk
Home automation device	Class 2	Must be reliable but not life-threatening
Industrial power control	Class 2	Needs longevity and fault tolerance
Aerospace telemetry board	Class 3	Extreme conditions, no tolerance for failure
Wearable medical monitor	Class 3	Safety-critical, patient health is at stake

How Global OEMs Define Assembly Classes

In North America and Europe, IPC standards are widely adopted but interpretation may vary slightly by industry. Some OEMs insist on Class 3 for any field-deployed IoT product, while others only reserve it for regulated sectors.

What’s changing now is the procurement mindset. OEMs aren’t just asking for compliance—they’re demanding documentation, traceability, and even continuous improvement plans from their EMS partners.

August Electronics is ahead of the curve by integrating digital QMS systems, traceability solutions, and regular client reporting: traits that global OEMs increasingly require.

The Canadian Advantage in High-Mix, Low-Volume Class 3

When it comes to mission-critical builds, Class 3 assemblies demand more than just precision; they require a manufacturing partner that’s equipped for complexity, responsiveness, and uncompromising quality. That’s where Canadian manufacturers like August Electronics excel.

Unlike high-volume facilities that prioritize scale, we specialize in low-to-high mix, low-to-mid volume production. This is especially well-suited to sectors where every component, connection, and compliance standard matters:

• Aerospace
• Clean energy
• Defense
• Precision medical devices

With a facility based in Calgary, Alberta, August offers several distinct advantages:

• Proximity to U.S. and Canadian markets for faster communication, shipping, and alignment
• NAFTA/CUSMA compliance for tariff-free trade and simplified logistics
• Access to robust, diversified supply chains that minimize risk and increase stability
• Collaborative processes that bring your engineers into the fold throughout the build

Class 3 manufacturing doesn’t scale easily and that’s exactly why Canada’s quality-first ecosystem is the right fit. At August, we don’t cut corners. We build relationships, ensure compliance, and stay hands-on every step of the way to support the industries that can’t afford to fail.

Final Thoughts on Class 1, 2 and 3 Assemblies

The IPC classification system isn’t just a technical guide, it’s a roadmap for ensuring your electronics perform where, when, and how they must. Whether you’re shipping toy drones or deep-space sensors, the right classification protects your product, your brand, and your users.

At August Electronics, we engineer trust into every board we build. Whether it’s a consumer device or a space-grade system, our commitment to quality, compliance, and client success defines the way we work and sets us apart in the world of electronics manufacturing. If you’re unsure where to start, let’s talk. We’ll help you match your vision to the correct class—efficiently, affordably, and accurately.

FAQs

What is the difference between Class 2 and 3 assemblies?

Class 3 requires tighter tolerances, higher inspection rigor, and zero-defect acceptance—ideal for mission-critical or life-dependent applications.

Can you upgrade from Class 1 to Class 3 later?

Not directly. Upgrading requires design changes, material revisions, and process revalidation. It’s best to determine the target class early in development.

Is Class 1 always cheaper?

Generally—but “cheap” can become expensive if product failures lead to returns, damage, or lost trust. You get what you pay for.

Do all manufacturers follow IPC standards?

No. Only IPC-certified manufacturers like August Electronics are trained and audited to apply IPC standards consistently.

How does August Electronics ensure class compliance?

We maintain in-house IPC-certified trainers, updated SOPs, advanced inspection tools, and a quality-first company culture.