How does traditional soldering work and where is it used?
Traditional soldering is a method of joining metals using an external heat source such as a soldering iron, reflow ovens or wave soldering (soft soldering), or a torch (brazing). In this process, the solder (the filler material) is heated to its melting temperature, allowing it to fill the gap between the joined components. After cooling, the solder forms a durable joint based on adhesion and capillary action.
The traditional soldering process consists of several stages:
- Cleaning the surfaces of the components to be soldered to ensure good adhesion.
- Applying flux, which prevents oxidation of the metals during heating.
- Heating the components to a temperature appropriate for the type of solder used (e.g. soft or hard/brazing).
- Introducing the solder in the form of wire, ring, or paste.
- Cooling the joint to obtain a durable bond.
Where is traditional soldering used?
Traditional soldering is used in various industries, especially where advanced technologies are not required. Example applications include:
- Electronics: Traditional soldering is widely used in mass production of electronic devices for soldering components onto PCB boards.
- Repairs and servicing: Soft soldering is commonly used in workshops, for example when repairing copper pipes or plumbing installations.
What is induction soldering?
Induction soldering is a method of joining metals that uses the principle of induction heating. In this process, heat is generated directly within the soldered components by eddy currents induced by an electromagnetic field. The heat produced in this way melts the solder, which fills the gap between the components and forms a durable joint.
How does the induction soldering process work?
Generation of the magnetic field:
An induction coil generates an alternating magnetic field that induces eddy currents in the metal components.
Heat generation:
The eddy currents cause rapid and localized heating of the material, allowing the solder’s melting temperature to be reached.
Joint formation:
The solder, applied in the form of a ring, paste, or wire, melts and fills the gap, creating a strong and tight joint.
Cooling:
Because only the soldering area is heated, heat is quickly dissipated into the remaining part of the component.
Advantages of induction soldering:
Precision:
Heat is generated only where it is needed, eliminating the risk of overheating surrounding materials.
Energy efficiency:
Energy is used exclusively to heat the soldered components, which minimizes thermal losses.
Process cleanliness:
The lack of direct contact between tools and components reduces the risk of contamination.
Safety:
This method eliminates the need for an open flame, reducing the risk of accidents.
Induction soldering is widely used in the electronics, automotive, and household appliance industries. This technology ensures high-quality joints, minimizes heating time, and is an ideal solution for companies that focus on efficiency and a modern approach to production.
Comparison of six areas between induction soldering and traditional soldering
Heating method
Traditional soldering:
Heat is supplied from an external source such as a soldering iron, a reflow oven, or wave soldering. These methods allow simultaneous heating of larger areas or multiple joints, which is particularly advantageous in mass production. In some applications, however, temperature distribution may be less uniform, especially when working with components that have high thermal mass.
Induction soldering:
Heat is generated directly within the soldered components by means of an electromagnetic field. This approach enables localized and selective heating of specific areas, which can be important for non-standard geometries or components with high thermal mass.
Energy efficiency
Traditional soldering:
Energy consumption includes heating a larger working zone, which is justified in high-volume processes where energy is distributed across a large number of joints produced simultaneously.
Induction soldering:
Energy is delivered mainly to the joint area, which can be advantageous in point or selective processes. Actual energy efficiency, however, depends on the specific application and production scale.
Precision and temperature control
Traditional soldering:
Provides stable thermal conditions in serial processes such as reflow or wave soldering. For non-standard components or parts with varying thermal mass, precise temperature control may require additional process optimization.
Induction soldering:
Enables precise control of heating parameters at a specific point. This is particularly useful in applications where controlling the temperature of a single joint without affecting surrounding components is important.
Process time
Traditional soldering:
Process time is optimized for continuous operation and high production volumes. Heating the entire working zone is efficient when joints are produced in series.
Induction soldering:
Allows rapid heating of a selected area, which can reduce the time of individual operations, especially for massive or difficult-to-heat components.
Workplace safety
Traditional soldering:
Involves working with hot components, ovens, or, in some cases, an open flame. These technologies are widely used and have well-established safety procedures.
Induction soldering:
The contactless process and the absence of an open flame can simplify workplace organization and reduce operator exposure to high temperatures, particularly in automated applications.
Application and flexibility
Traditional soldering:
Best suited for mass production of standard components and easy to integrate into high-throughput production lines.
Induction soldering:
Used mainly in specialized applications such as selective soldering, components with high thermal mass, or non-standard joints. It can be effectively integrated with automation systems in medium- and high-volume production.
When should you choose which method – is induction soldering always better?
Induction soldering is a modern technology, but it is not a universal replacement for traditional methods. In practice, both conventional processes (such as reflow, wave soldering, or hand soldering) and induction soldering are effective—the key is selecting the right method for the specific application, production scale, component type, and investment budget.
When to choose traditional soldering?
Low-volume production, prototyping, and repairs:
For small batches and workshop-type work, traditional methods are usually simpler to implement and more cost-effective.
Standard, repeatable mass-production processes:
Reflow and wave soldering are proven standards in electronics manufacturing and work very well in large-scale production, especially for typical PCBs and components.
Lower entry threshold (cost and organization):
Conventional technologies generally require lower initial investment and are more readily available in many production facilities.
No need for selective heating:
When there is no risk of overheating neighboring components or when heating a larger area is acceptable, traditional methods are fully sufficient.
When to choose induction soldering?
Selective or point soldering:
When a specific area must be heated without affecting surrounding components (e.g. joints near temperature-sensitive parts, connections to metal housings, or non-standard mounting locations).
Components with high thermal mass:
Such as large connectors, wires, heat sinks, or terminals—applications where conventional methods may require longer heating times or make it more difficult to achieve a stable temperature profile.
Processes requiring high repeatability on a specific part:
Induction soldering often performs well in production where the same type of joint is repeatedly made on similar components.
Automation of point operations:
In production lines where repeatable “soldering stations” are needed for selected joints, induction soldering can be effectively integrated as one stage of the overall process.
Is induction soldering always better?
No. Induction soldering can be very beneficial in specific, more demanding applications and selective processes, but in many typical high-volume implementations, conventional methods (reflow or wave soldering) are equally effective, less expensive to implement, and well established from a technological standpoint. Therefore, the choice should be based on a thorough analysis of what is being soldered, at what scale, what thermal constraints the components have, and what quality and cost requirements the process must meet.
If needed, this section can be made even more neutral by explicitly stating that in electronics manufacturing, reflow and wave soldering most often remain the first choice, while induction soldering serves as a tool for special tasks (such as components with high thermal mass, selective joints, or non-standard geometries).
Energy Waves – we will implement the right processes in your company
At Energy Waves, we understand that every business has unique needs, which is why we offer comprehensive support in selecting and implementing the most suitable soldering processes—both induction and traditional. With our experience, we help companies achieve higher efficiency, better quality, and real cost savings.
Why choose Energy Waves?
Individual approach:
We analyze the specifics of your production and select the technology that best fits your requirements.
Modern solutions:
We specialize in designing induction soldering systems that improve energy efficiency and production quality.
Support at every stage:
From process audits, through system design and installation, to team training—we provide end-to-end support.
Experience and trust:
Our solutions have been implemented in well-known companies across various industries, including automotive, electronics, and tool manufacturing.
Cost optimization:
We help reduce energy consumption, minimize waste, and shorten process times, resulting in tangible savings.
Whether your company is just starting to use soldering technologies or planning to modernize existing processes, you can rely on our support. Entrust us with the implementation of modern and efficient soldering methods—together we will take your production to the next level.