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A challenge in selecting and applying lead‐free solders lies in separating the influences of materials' properties, fluxes and processes to obtain robust assembly conditions that are compatible with PCB finishes and all component terminations. This paper discusses simple steps towards establishing a lead‐free assembly process. With reference to results of solder paste spread and wetting tests and component solderability tests, some of the current limitations in applying standard test methods to lead‐free evaluations are highlighted.