Hi Chris-

One common way of doing this is to add some unplated holes to create a wire
clamp and strain relief loop. The wire goes through the unplated hole and
then loops over to the SMT contact or plated hole. Usually a dot of glue or
RTV is added to lock the wire into the unplated hole.

Wayne THayer

On Fri, Mar 4, 2022 at 6:17 AM <
[log in to unmask]> wrote:

> Does anyone have recommendations for best assembly practices when
> soldering 28-30awg stranded wire directly to PCB PTHs? There seems to be
> high risk for fatigue and wire break above the solder joint that would make
> this assembly process unreliable. I have seen solderable crimp pins used
> but those tend to add vertical height off the PCB that can be an issue in
> low profile applications. Stress relief and wire staking can help to
> stabilize the wire to prevent breakage, but this can also be difficult in
> densely populated areas on the board.
>
> Chris Thierolf
> Senior Specialist, Electrical Engineer
> Integrated mission systems / L3HARRIS TECHNOLOGIES
> t +1 215 698 6390
>
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