In the world of electronics manufacturing, surface mount technology (SMT) has become the standard for producing compact, high-performance printed circuit boards (PCBs). One key to maintaining efficiency and minimizing downtime on an SMT production line is the use of surface mount splice tape—a small but powerful component that plays a critical role in continuous, uninterrupted assembly.

This article explores what surface mount splice tape is, how it works, the types available, and why it’s essential for modern electronics production.

What Is Surface Mount Splice Tape?

Surface mount splice tape is a specialized adhesive tape used to join two ends of carrier tape—the tape that holds SMT components during automated pick-and-place processes. When a reel of components is nearly empty, splice tape allows a new reel to be seamlessly connected without stopping the machine.

It’s a vital consumable in SMT operations, helping to keep production lines running by enabling smooth reel-to-reel transitions.

Why Use Surface Mount Splice Tape?

Downtime in SMT production is costly. Manually stopping a pick-and-place machine to reload a new component reel takes time, disrupts production flow, and increases labor costs. Surface mount splice tape helps mitigate these challenges in several key ways:

✅ 1. Continuous Operation

Splice tape enables operators to prepare and connect a new reel before the previous one runs out, ensuring the machine can continue running without interruption.

✅ 2. Reduced Waste

Without splice tape, the last few components on a reel might be discarded during changeovers. By splicing reels together, manufacturers can utilize the full length of each carrier tape, minimizing component waste.

✅ 3. Cost Efficiency

Less waste and less downtime translate directly into lower operating costs. Over time, especially in high-volume production, this can lead to significant savings.

✅ 4. Improved Line Efficiency

By avoiding machine stops, production remains smoother and more consistent. This improves takt time, throughput, and overall equipment effectiveness (OEE).

Types of Surface Mount Splice Tape

There are several different forms of surface mount splice tape available, each suited for specific equipment, processes, or operator preferences:

🔹 Single Splice Tape

• The most basic form.
  
  

• Typically pre-cut and color-coded for ease of use.
  
  

• Often paired with metal shims or staples to reinforce the splice.
  
  

🔹 Double Splice Tape

• Offers stronger adhesion and better alignment.
  
  

• Provides a wider bonding area for added security, especially in high-speed pick-and-place systems.
  
  

• Often used with precision splice tools.
  
  

🔹 Shim-Integrated Splice Tape

• Combines the splice tape with a pre-attached shim or alignment pin.
  
  

• Ensures perfect pitch and hole alignment, reducing feeding issues in automatic feeders.
  
  

🔹 ESD-Safe Splice Tape

• Designed for use in electrostatic-sensitive environments.
  
  

• Prevents damage to sensitive components during the splicing process.
  
  

How to Apply Surface Mount Splice Tape

Using surface mount splice tape correctly is key to avoiding feeder jams or placement errors. Here’s a general process:

1. Stop the carrier tape at the end of the current reel—leave several inches accessible.
   
   

2. Prepare the new reel’s tape, aligning it with the trailing end of the current reel.
   
   

3. Use a splice tool (manual or automatic) to align and apply the surface mount splice tape precisely over the junction.
   
   

4. Reinforce with shims or extenders if needed (especially for wider tapes or high-speed lines).
   
   

5. Resume feeding, ensuring the splice passes smoothly through the tape feeder.
   
   

Most high-quality splice tapes come with alignment guides or can be used with tools to eliminate human error.

Applications of Surface Mount Splice Tape

Surface mount splice tape is used in virtually all industries that rely on SMT manufacturing, including:

• Consumer Electronics – phones, tablets, and home devices
  
  

• Automotive Electronics – sensors, control units, displays
  
  

• Medical Devices – monitors, wearables, diagnostic tools
  
  

• Industrial Automation – PLCs, sensor arrays, controllers
  
  

• Aerospace and Defense – high-reliability control systems
  
  

Any environment using automated pick-and-place machinery benefits from efficient reel splicing.

Choosing the Right Surface Mount Splice Tape

Not all splice tapes are created equal. When selecting the best solution, consider:

• Tape width compatibility (e.g., 8mm, 12mm, 16mm, 24mm)
  
  

• Feeder type and speed (some high-speed feeders require stronger adhesion)
  
  

• Component sensitivity (opt for ESD-safe if needed)
  
  

• Environment (heat, humidity, and dust resistance may be required)
  
  

• Certification (IPC-compliant splice tape ensures quality and industry standardization

Best Practices for Splicing SMT Tape

To maximize the performance of surface mount splice tape:

• Train operators on proper alignment and handling techniques.
  
  

• Use precision tools to improve accuracy and repeatability.
  
  

• Inspect splices regularly for mechanical integrity.
  
  

• Keep tapes and tools clean to prevent feeder contamination.
  
  

• Document splice points in quality control logs for traceability.
  
  

Conclusion: Surface Mount Splice Tape—A Small Product with a Big Impact

In today’s lean manufacturing landscape, every second counts. Surface mount splice tape is an essential part of any SMT production strategy, enabling faster reel changes, less waste, and higher productivity. While simple in appearance, these tapes play a critical role in ensuring continuous, reliable, and cost-effective PCB assembly.

Whether you're running a high-volume electronics factory or a short-run prototyping line, investing in the right splice tapes—and using them effectively—can deliver major operational advantages.