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W. Edwards Deming’s Lost Chapters Recovered
08/12/2020 | Happy Holden, I-Connect007
8 Measures for Sales and Operations Planning in Turbulent Times, Part 8
08/12/2020 | Fane Friberg, CEPHAS
8 Measures for Sales and Operations Planning in Turbulent Times, Part 7
08/11/2020 | Fane Friberg, CEPHAS
8 Measures for Sales and Operations Planning in Turbulent Times, Part 6
08/10/2020 | Fane Friberg, CEPHAS
I-Connect007 Editor's Choice: 5 Must-Reads for the Week
08/07/2020 | Nolan Johnson, I-Connect007
PCB :: Fabrication Process
Factors Affecting the Adhesion of Thin Film Copper on Polyimide
The use of copper foils laminated to polyimide (PI) as flexible printed circuit board precursor is a standard practice in the PCB industry. We have previously described an approach to very thin copper laminates of coating uniform layers of nano copper inks and converting them into conductive foils via photonic sintering with a multi-bulb conveyor system, which is consistent with roll-to-roll manufacturing.
All About Flex: FAQs on RoHS for Flex Circuits
In 2003, the European Union (EU) adopted a standard called the Restriction of Hazardous Substances (RoHS), which restricts the use of certain materials in electronic products and electronic equipment. The intent is to reduce the environmental impact of known hazardous materials and has driven changes in manufacturing processes and materials used to manufacture a wide array of electronic products.
Happy’s Essential Skills: CIM and Automation Planning, Part 1
There is a lot of talk and information about automation, but I find that there is very little available on automation planning. This is one of my specialties. I started by getting a master's in EE in control theory. This went well with my B.S. in chemical engineering as I specialized in process control and IC manufacturing.
All About Flex: Soldering Flexible Circuits
The most common methods for component attachment on flexible circuits and rigid printed circuit boards involve soldering. The basic principles for soldering are the same for both flex and hard board, but soldering components to flexible circuits involves certain specific considerations vs. our rigid cousins.
Happy’s Essential Skills: Quality Functional Deployment (QFD)
Wikipedia has one of the best definitions of quality function deployment (QFD): “QFD is a method to help transform customer needs (the voice of the customer or VOC) into engineering characteristics (and appropriate test methods) for a product or service. It helps create operational definitions of the requirements, which may be vague when first expressed. It prioritizes each product or service characteristic while simultaneously setting development targets for the product or service.”
Spirit Circuits: Building a New Factory in Romania...
Recently I sat down with Managing Director Steve Driver of Spirit Circuits. We discussed the company’s future, and the interesting decision to build a new facility in Craiova, Romania, and how Whelen’s Alex Stepinski influenced the design.
FTG: Focus to Expand
Firan Technology Group (FTG) is a Canadian circuit board and cockpit product manufacturer. With a newly established global footprint, they look now to grow within that footprint, particularly by way of acquisition. I-Connect007’s Judy Warner and Barry Matties met CEO Brad Bourne at FTG’s Chatsworth, California facility to learn more about the acquisitions, their success in China, and the overall challenge of working in the aerospace and defense market.
Happy’s Essential Skills: Roadmapping Essentials
Many industries recognize value and benefits in technical roadmapping. However, misuse leads to abundant dangers and can render a technology roadmap useless, or worse. Good roadmaps embrace uncertainty, exploiting apparent weakness to derive maximum insight and understanding. The Technology Roadmapping Handbook from the University of Leipzig is a useful roadmapping reference.
Trouble in Your Tank: Building Reliability into the PCB, Part 2
In Part 1 of this column on reliability, I presented the common PTH failures encountered when reliability is less than robust. PTH reliability is influenced by several factors including the quality of the PTH after drilling, plating thickness and plating distribution in the PTH. In this column, I will present additional factors, including the Coffin-Manson model in the context of understanding reliability failures.
Catching up with Artnet Pro’s Meir Polack
Interested in all aspects of our industry, I have lately been especially focused on our suppliers, because more and more of my board shop clients are concerned about their vendor support chain as more of them are either reducing their presence in North America or leaving altogether. I am also keenly interested in companies whose mission it is to help the PCB industry survive, especially a company that does not abandon the “little guys,” but rather is focused on helping those smaller companies to compete with the giants whose goal is to run them over.
Event Review: 7th Electronic Materials and Processes for Space Workshop
This year's Electronic Materials and Processes for Space Workshop discussed a wide range of technology issues and developments when it comes to PCB fabrication and assembly for space applications. From addressing reliability issues to dealing with cracks that may form during thermal cycling, to REACH regulations and their impact on space hardware, and tin whisker growths. Barrie Dunn provides the highlights.
If you have paid any attention at all to our newsletters and other publications, you should have been aware of this month’s topic long before opening this magazine. We tried to reach… everybody, so we could get their thoughts on the industry for this issue.
Happy’s Essential Skills: Engineering Economics (ROI)
Engineering economics is fundamental in engineering, especially for manufacturing support. For simplicity, I am using the term here as a process engineer for printed circuit equipment and automation of production.
A Day with Pete (Starkey)
Usually the one conducting the interviews, I-Connect007’s own Pete Starkey recently found himself on the other side of the microphone when I spent time with him in his hometown of Market Bosworth, England. There, between hiking and gardening, we found time to discuss Pete’s rich history in the PCB industry and the many changes and surprises he’s seen in the manufacturing process over the years.
Shane Whiteside and Summit Interconnect: Aspiring to New Heights
A few weeks ago I was privileged to meet with Shane Whiteside in Anaheim, California, at KCA Electronics. Whiteside, former COO of TTM, has helped launch a new company—Summit Interconnect— which encompasses the recent acquisition of KCA Electronics and Marcel Electronics International. Once again assuming an executive role, this time as CEO and president, Whiteside shared his story, strategy and vision for this new chapter.
Happy’s Essential Skills: Benchmarking
Benchmarking is a process that measures how a company is performing against those industry leaders. It is used to better understand how outstanding companies perform, and then helps your company develop plans to improve or adapt specific best practices.
This month's column has a higher percentage of IC coverage than normal for several reasons. The end of Moore's Law regarding transistor scaling will be dead by 2021 as will be replaced by 3D integration according to the International Technology Roadmap for Semiconductors (ITRS).
All About Flex: Creating Via Holes in Flexible Laminates
Almost all double-sided and multilayer flexible circuits require through-holes or vias to enable an electrical connection between conductive layers. Creating a reliable plated via requires several critical steps. The first one is creating the through-hole.
Inside Spirit Circuits
I was recently treated to a factory tour with Spirit Circuits’ Managing Director Martin Randall, to learn more about their process line and how it has evolved over time. In the discussion following, I learned about Spirit’s involvement in the China market and how they’ve structured their business to handle quick turn prototypes locally and high volume abroad.
High-Throw Electroless Copper– New Opportunities for IC Substrates and HDI Manufacturing
The one constant in electronics manufacturing is change. Moore’s Law, which successfully predicted a rate of change at which transistor counts doubled on integrated circuits (ICs) at lower cost for decades, is ceding to be an appropriate prediction tool.
Using the Type 1 Gauge Study to Assess Measurement Capability
Measurement capability is a critical aspect of ensuring product quality, therefore a measurement system must be assessed before being used on products. Understanding how to assess measurement capability becomes critical. The Type 1 Gauge study is typically the first step in a measurement system analysis program. Type 1 Gauge parameters are explained, and a worked example using electroless nickel immersion gold (ENIG) is provided.
A Thermal Conductivity Measurement Method, Adapted to Composite Materials Used in the PCB Industry
Most of today’s printed circuit board base materials are anisotropic and it is not possible to use a simple method to measure thermal conductivity along the different axes, especially when a good accuracy is expected. Few base material suppliers’ datasheets show X, Y and Z thermal conductivities. In most cases, a single value is given, moreover determined with a generic methodology, and not necessarily adapted to the reality of glass-reinforced composites with a strong anisotropy.
Round Robin of High-Frequency Test Methods by IPC-D24C Task Group (Part 1)
Currently there is no industry standard test method for measuring dielectric properties of circuit board materials at frequencies greater than about 10 GHz. Various materials vendors and test labs take different approaches to determine these properties. It is common for these different approaches to yield varying values of key properties like permittivity and loss tangent.
Made in Brazil: The Evolution and Revolution of Impedance Control in PCB Production
The PCB industry in Brazil has gone through several changes over the last decade. Our customers have been demanding better quality and higher-reliability products more than ever before, but few things have changed as much as impedance control. PCBs with impedance control requirements have become the engine of the market, and finding solutions to fit the customer’s needs is extremely challenging.
Viking Test Services: Much More than Test
Recently, 007 Technical Editor Pete Starkey and I toured Viking Test’s facility in Hants, UK where we met Managing Director Jake Kelly to learn about the history of the company, their recent involvement in the Indian PCB market, and what he thought of the EIPC Summer Conference.
Testing Todd: Test & Measurement—The Case for Validation
Test and measurement (T&M) are terms that can strike fear into the most robust of minds. Many engineers create designs and products of the future with specific results predicted for performance.
Faster, More Accurate AOI is More Important than Ever
Among PCB manufacturers, there is a common perception that AOI has not changed much since it was introduced decades ago. Over the last few years, however, new advanced technologies have made AOI solutions smarter, faster and much more accurate. AOI system data have even been integrated with newly developed automatic 3D shaping tools.
Patty's Perspective: Delving into Test and Inspection
I’ve always been a wet processing person, if not always in a PCB shop, at least at heart. My undergraduate degree is in chemistry and I cut my teeth working on electroless copper processes (just a metaphor, mind you!). Testing, testing and more testing in R&D can be sooo boring and repetitive.
Catching up with Sunrise Electronics’ Ashok and Jigar Patel
I had been hearing about Sunrise Electronics for many years, so when Ashok asked me to come and see them for myself, I jumped at the chance. It was one of the most amazing plant tours that I’ve been on in a long time. I wanted to know more, so we sat down and had a chat.
Standard of Excellence: The Future is in Fine lines
The age of much finer lines and spaces is upon us. After years of slowly moving towards this technology our customers are now demanding that all of us provide them with fine lines and spaces. Our new trend in electronics is for denser and denser circuitry on smaller and smaller real estate.
The Newest Flex Shop in the U.S.
I-Connect007 sales team member Angela Alexander and I recently got a tour of Lenthor’s new Silicon Valley flex board shop and then sat down with President and CEO Mark Lencioni to discuss the new flex facility, the markets, management, and the future.
The way that I see the problem relates to overcapacity for fabricators in the consumer segment of devices with flat panel displays—mobile and otherwise—as well as a decline in notebook PCs, TVs and other household and portable electronic devices. Additional culprits include the improved packaging designs as well as more powerful chips replacing multiple ICs—both requiring less board real estate.
The 21st Century PCB Factory– Designed to Eliminate Offshore Cost Advantages
Over 15 years have passed since North America and Europe ceased being the center of worldwide PCB fabrication and were supplanted by a Chinese market with low-cost labor, lax environmental requirements, and strong government support. In just a few short years, the superior offshore cost advantages of this new dynamic put volume PCB production in the West out of business, aside from the military and specialty technology applications contained in the few shops that continue to exist today.
Happy’s Essential Skills: Design for Manufacturing and Assembly, Part 2
Advances in interconnection technologies have occurred in response to the evolution of component packages, electronic technology and increasing complex functions. Therefore, it comes as no surprise that various forms of printed wiring remains the most popular and cost effective method of interconnections.
Happy’s Essential Skills: Design for Manufacturing and Assembly, Part 1
Advances in interconnection technologies have occurred in response to the evolution of component packages, electronic technology and increasing complex functions. Therefore, it comes as no surprise that various forms of printed wiring remain the most popular and cost-effective method of interconnections.
Sensible Design: Coatings—Five Essentials for Designers
In an ideal world, PCB designs would not have an inherent weak point for corrosion; unfortunately, in the real world, they do. When a weak point is revealed, you are better equipped to deal with it. Often the spacing of components, board finish and distance to ground planes can be optimised for corrosion resistance.
All About Flex: Imaging Methods for Etch Resist, Part 3: LDI
When LDI technology was first introduced around 20 years ago, throughput was an issue. LDI was often restricted to low volume or prototype runs. Subsequent advances in equipment as well as faster acting photoresist have made it practical for high volume circuit fabrication.
All About Flex: Common Flex Circuit Surface Finish Requirements
Copper is a unique metal and has been proven with the test of time in an incredible array of printed circuit and electrical wiring applications. It is highly conductive, has good flexibility properties, can withstand high temperatures and has good chemical resistance. Copper is also is in abundant supply and is fairly inexpensive.
RTW IPC APEX EXPO: Taiyo America Talks Inkjet Solder Masks and 3D Printing
Josh Goldberg of Taiyo America speaks with I-Connect007 guest editor Steve Williams about some of the latest innovations happening in his company, including inkjet solder masks, and how they lend to small runs and rapid prototyping type of development work, especially with the idea of doing an additive manufacturing process.
EIPC Summer Conference 2016, Day 2: Strategies to Maintain Profitability in the European PCB Industry
Delegates awoke to a gloomy Scottish morning on the second day of the EIPC Summer Conference 2016. One or two who maybe overindulged in the whisky on the previous evening had some difficulty in finding time for breakfast before the conference proceedings, but the atmosphere in the meeting room was brighter than the weather outside, as Professor Martin Goosey introduced the day’s programme.
The Sum of All Parts: The Fabricator-Assembler Connection
After discussing the relationship between PCB fabricators and those who design the boards (see my previous column ), it is imperative to do the same for the relationship between assemblers and fabricators. This brings about a whole new set of potential complications.
Ken Moffat of American Standard Circuits Talks Aerospace Accreditation, DfM, and More
At the recent SMTA West Penn Expo & Tech Forum, I had the opportunity to speak with Ken Moffat, of American Standard Circuits, based in Chicago. Among the topics we discussed was the importance of attending local chapter shows like this one, and ASC’s value-added services such as DfM, especially in the metal-backed and RF arenas.
All About Flex: Plating Process Options for Flexible Circuits
Plating copper through-holes or vias is a requirement for double-sided and multilayer circuits. In a previous column we discussed the plating process; specifically copper seed coating using electroless copper and Shadow plating, which is then followed with an electroplating process.
EIPC Summer Conference 2016, Day 1: Strategies to Maintain Profitability in the European PCB Industry
Resplendent in the kilt, EIPC chairman Alun Morgan welcomed a large and enthusiastic gathering of printed circuit professionals from all over Europe and as far afield as the USA, Canada and Russia, to the EIPC Summer Conference 2016 in Edinburgh, Scotland's cosmopolitan capital city.
Happy’s Essential Skills: Producibility and Other Figures of Merit
Metrics are data and statistically backed measures. It is always expedient to base decisions on data and metrics, for example, in PCB design. These measures can be density, first-pass yield connectivity or in this context, producibility. These measures are the basis for predicting and planning a printed circuit design. But what if a metric doesn’t exist? Then you can create the next best measure, the Figure of Merit.
Book Review: Beating the Workplace Bully
There’s the woman who conned her co-worker into buying her coffee on the first day and then made it a daily event. Or the boss who was always threatening to fire his staff and telling them, “There’s blood in the water.” Or the supervisor who told her new employee on the first day that it was not her choice to hire her, because she had only worked in a small firm and “did not have the sophistication this corporate position needs. You don’t even dress properly.” This great book is full of such terrible people.
RTW IPC APEX EXPO: Matrix Highlights How Dry Film Laminator Addresses Fine Line Challenges
Fred Long, business development manager at Matrix USA, talks to I-Connect007 guest editor Dan Feinberg about how a new pressure system in the Hakuto Dry Film Laminator provides even heat and pressure along the entire length of the pressing cycle system to address the challenges of circuits with finer lines.
Institute of Circuit Technology Annual Symposium
On June 1, Technical Director Bill Wilkie introduced the 42nd Annual Symposium of the Institute of Circuit Technology, at the Motorcycle Museum in Birmingham, UK, commenting upon the success of the recent Foundation Course and acknowledging the sterling efforts of his course tutors, although recognising that some of his longest-standing experts were now retiring.
Trouble in Your Tank: Primary Imaging for Pattern Plating, Part 2—Development
The proper development of the primary photoresist is critical to the overall success of the imaging process and in turn the processes that follow—either etching to form innerlayers or the electroplating processes on outer layers. In this step, the unexposed photoresist (after resist lamination and exposure) is washed away via the developing process.
The Shaughnessy Report: The Designer Roundtable Roundup
Every year, I attend SMTA Atlanta, just across town. You have to love a local trade show. No airlines, no jet lag, and no hotels. It’s a small show; it would fit in a school gymnasium. But for me, the highpoint of SMTA Atlanta is the Designers Roundtable. This year the roundtable had 15 attendees, up from 12 last year. Two of the new attendees were under 35, which surprised all of us "graybeards."
Multilayer's Viny Mulani on what it Takes to Survive Offshoring
As the leader of one of the surviving PCB shops in the United States, Multilayer Technology's President Viny Mulani has a unique perspective. He sat down with I-Connect007's Barry Matties recently at IPC APEX EXPO 2016 to discuss what kind of machinery he’s looking to invest in to keep more business from moving offshore.
New Management and Strategies at eSurface
At the recent Geek-A-Palooza, I spoke with Alex Richardson and Rick McCann of eSurface Technologies, to learn about the condition of the company, their new semi-additive approach, and a couple of big announcements.
Global Technology Development: HDP User Group European Meeting 2016
Delighted and honoured to be invited again to attend the open session of the High Density Packaging User Group (HDPUG) European Meeting, I made my way to the picturesque Grand Duchy of Luxembourg, a tiny principality bordered by Belgium, France and Germany, and ranked among the world's top-three nations in both wealth and wine consumption, to learn about the latest in collaborative research and development by member companies engaged in the manufacture of products utilising high-density electronic packages.
Happy’s Essential Skills: Learning Theory/Learning Curves
Learning is not instantaneous! Nor is progress made in a steady manner, but at a rate that is typified by one of two basic patterns. In some cases, plateaus will be seen in learning curves. These are caused by factors such as fatigue, poor motivation, loss of interest, or needing time to absorb all the material before progressing to new. This column will not go into details of how learning is achieved, but will summarize some of these theories.
Gen Consulting Company (GCC) has issued the Radiant Insights report “Global HDI Printed Circuit Board Market Forecast and Analysis 2016-2021.” The report provides a detailed analysis of worldwide markets for HDI printed circuit boards from 2011–2016, and provides market forecasts for 2016–2021 by region/country and subsectors.
All About Flex: Flexible Circuit Fabrication and Cleanroom Manufacturing
Facility cleanliness is a vital part of process control for flexible circuit fabricators. As higher density requirements continue a relentless drive toward finer traces and spaces, particles and foreign material can cause problems in a number of operations.
MACFEST—Manufacturing Advanced Coatings for Future Electronic Systems
Now in its second year, MACFEST is a collaborative research project involving partners A-Gas Electronic Materials, C-Tech Innovation, MTG Research, the Institute of Circuit Technology, the University of Leicester and Merlin Circuit Technology.
Case Study: Reducing Defects Caused by Excess Handling and Mishandling
Most folks associate quality improvement initiatives with upfront expenses and ongoing cost increases. Fortunately, when done efficiently and with enough forethought and planning, quality improvement programs can pay for themselves in the form of increased throughput, reduced labor steps, and reduction in materials consumption.
Standard of Excellence: LED and Metal-Backed Technology—Today and in the Future
Probably one of the hottest, or should I say coolest, technologies today is LED. I would also venture to say it is one of the fastest growing as well. All you have to do is look around you can see evidence of this everywhere from holiday lights in your home and Jumbotrons at sports arenas, to highway and business signage. The lighting industry is now dominated by LED technology.
BOOK REVIEW: Printed Circuits Handbook, Seventh Edition, 2016 (McGraw-Hill)
The Printed Circuits Handbook has been a classic reference to the industry for many years, and the new edition will assure its place for years to come. The 7th Edition features 71 chapters, four more than the last edition, structured in 12 parts, and authored by 38 contributors—a list of accomplished authors that could double as a who’s who in the world of circuit boards.
All About Flex: Imaging Methods for Etch Resist, Part 2: Photoimaging
This is the second of three columns describing typical methods for creating an etch resist for fabrication of printed circuits. Photoresist can come in the form of a liquid that gets coated on the substrate or as a dry film that is laminated. Liquid and dry film resist can be positive-acting or negative-acting.
PE on 3D objects
I recently sat down with Mike O’Reilly of Optomec to discuss 3D printing onto existing substrates and small polymer-based additive manufacturing pieces and how that impacts PCB manufacturing. Mike also discuss the benefits of printing with conductive epoxies versus the traditional solder process, and where Optomec fits in to the burgeoning 3D market, going forward.
Beyond FR-4: High Performance Materials for Advanced Designs, Part 2
In Part One we covered basic FR-4 and variants that have been used in the commercial and military market for the past few decades, but in this column we will delve into the newer materials that target a specific application and/or market segment.
Happy’s Essential Skills: Project/Product Life Cycle
The product, and or project (process) life cycle (PLC) is fundamental to a corporation intent on developing new products or processes. It sometimes is called the new product introduction (NPI) process but that is only half of the life cycle. There is product support, enhancement and eventually, obsolescence.
The Sum of All Parts: Planning for a First-Time-Right PCB Design
The development of highly integrated and high-speed, chip-based circuit boards brings several functional benefits. But at the same time, these can introduce additional challenges to the actual board itself. Therefore, developing an effective plan for designing, developing, testing and producing the final PCBs is a good business practice.
The Future of Computer-Integrated Manufacturing in the PCB Industry
Computer-integrated manufacturing is already a proven reality in the PCB industry for those prepared to make the investment, and results in improved quality and reduced costs. The biggest barrier to its general adoption is the reluctance of some equipment manufacturers to communicate in a uniform data format.
Stepping up to Laser Processing for Flex, Part 3: Readiness and Site Preparation
With so many processes to keep track of in a flex manufacturing line, it can be easy to get lost in the details and begin to rely on your suppliers to address any issues that might crop up. However, given that laser processing equipment and flex materials are both impacted by your facilities, your attention to and investment in clean, stable, and robust facilities and support equipment will quickly pay off in less downtime, higher yield, and—perhaps most importantly—fewer headaches!
Orbotech’s Latest Technology at IPC APEX EXPO
Orbotech presented their latest new technologies at IPC APEX EXPO 2016. The Nuvogo 1000 is a higher power version of their multi wavelength direct imaging machine, as well as their new automated optical shaping technology which can add copper deposition to an otherwise defective PCB. I met with Orbotech’s Micha Perlman in their booth on the show floor, to learn more.
All About Flex: Imaging Methods for Etch Resist, Part 1
Imaging is a major process step in creating a copper circuit or flexible PCB. In single-sided circuit fabrication, the imaging process creates the resist pattern that protects the copper from the etchant. It is critical that this pattern precisely define the circuit traces, as issues with imaging will transfer to the subsequent processes.
Koen Hollevoet Explains Rogers' New PEEK-based Material for Extreme Temps
Rogers has been developing a new material called XT/duroid laminate, which is based on polyether ether ketone (PEEK) material and can withstand some of the harshest temperatures and environments. I met with Koen Hollevoet, Business Development Manager at Rogers Corporation, at IPC APEX EXPO 2016 to further discuss this material and learn how it might benefit the PCB market.
IEC: Celebrating 50 Years in Business
I caught up with Shawn Stone of IEC recently, to discuss plating, laminates, printed electronics and IEC’s many strategic alliances, including their most recent agreement with ITEQ to distribute their copper-clad laminate line throughout North America. This alliance will give IEC, a company his father started more than 50 years ago, its first North American footprint.
Ventec International Group Expands North American Focus
Ventec International Group is looking to expand their U.S. operations, and they’ve begun this process by bringing Chris Alessio on board as VP of sales and operations of Ventec USA. I met with Chris and Ventec USA President Jack Pattie at IPC APEX EXPO 2016 to discuss their approach and possible opportunities for the North American laminate market.
Nano System, Two Years On
Established in July 2014, Nano System Inc. focuses on the design and manufacture of laser drill systems for the PCB industry. I-Connect007's Stephen Las Marias caught up with Nano System President Sam Sekine last month at IPC APEX EXPO to discuss the latest product and business developments at his company.
Rogers: 'To PIM-test Our Material, You Have to Build a Circuit'
Passive intermodulation (PIM) is a circuit anomaly that has been occurring in cellular base station antennas, causing tremendous frustration and cost to antenna OEMs. As the supplier of the materials being used by these OEMs, Rogers Corp., and more specifically, Product Manager Tony Mattingly, must come up with a solution.
Happy’s Essential Skills: Using Web Resources
The World Wide Web is a real boon to information retrieval. The key is getting to relevant information and not being overwhelmed by the sheer number of references. When confronted with a process problem, the urgency of a solution requires that you know how to use Web resources expeditiously.
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