PROCESS You can find more information on our web, so please take a look.
INDUSTRY STANDARD
SATURN ELECTRONICS
Multiple sheet sizes that are sheared to size in-house.
18"x24" panels with saw-cut edges reduce contamination in subsequent processes (e.g., imaging, testing, etc.). This also reduces set up times and variation associated therein.
IMAGING / EXPOSURECustomer artwork is aligned manually by eyeballing the registration of the film to the drilled panel.
Light source is a single point light source, making it not possible to use on fine line images run on production panel sizes.
Automated (inner layers): Saturn also employs the use of an Olec AX-28 automatic exposure unit that uses two cameras to align the top and bottom artwork. This machine can hold registration as tight as +/- . mils front to back for inner layers.
Auto-Alignment (inner and outer layers): Saturn has purchased and installed four Olec AT-30 automatic alignment exposure units. These units use four cameras to align artwork top to bottom, and then use panel motion systems to automatically adjust the panel position to a best fit to the artwork. Furthermore, these units have hybrid-collimated light units that ensure exposure light attacks the panel at 90 degree angles to the artwork, which is critical for fine line resolutions.
Direct Imaging: Saturn has two Orbotech LDI Laser Based Direct Imaging Systems to facilitate fine line imaging and optimum registration on non-rigid materials, which is ideal for HDI Technology.
Most Fabricators do not have a dedicated inner layer etching process. Instead they use their outer layer etching line which requires 2 full-time Operators and Leader Boards for thin core transport.
Newly-installed () Develop-Etch-Strip (DES) line featuring thin core handling to enable complete automation down to 0.001" flex cores without leader boards.
Full-time operator no longer required as new line features a loader, cover sheet remover, and unloader. Capable of producing 240 1 oz. cores per hour. Furthermore, this line has a vacuum etching option that minimizes top-to-bottom etch variation, which is ideal for HDI Technology.
Visual inspection by personnel using a light table.
We recently installed 2 Camtek Phoenix HDI AOI systems for scanning high-density, complex PCBs. The system's new optical technology provides flexible light coverage by combining a superior image with customizable detection requirements, which is ideal for HDI Technology.
New AOI Features:
1.
Software imports true ODB++ file format so that feature identities (ground plane, pad, trace, etc.) are imported.2.
False calls reduced by more than 90%.Drilling machine that requires tools to be changed manually.
Maximum panel sizes are typically 18&#; x 24&#;.
No control in Z-axis, +/- 0.002&#; hole position accuracy.
To address HDI needs and provide a true mass-production solution, Saturn has a 3-step process. First, we have installed a fully automated Pluritec Inspecta Combo X-Ray Drilling System which optimizes registration on up to 200 panels per batch, all without operator intervention.
Next, our two recently-installed fully automated LENZ Multi Spindle DLG systems feature vision aided linear motors capable of &#; / minute and +/- 0.&#; XYZ tolerance; and a dual spindle loading magazine in back to eliminate need for operator presence between cycles to provide true lights-out operation.
Finally, the Excellon Cobra Hybrid Laser system features both UV and IR (CO2) laser capabilities to cover a wide range of flex circuit and rigid-flex circuit processing applications, in addition to optimized laser via drilling capabilities. The Combination of these drilling systems provide the ideal solution for fabricating HDI Technology.
For standard multi-layer technologies, SEC has installed numerous volume capability Mania Micronics drilling machines incorporating the industry&#;s latest linear motion technology and 180k RPM high speed spindles. The use of linear motion increases hole position accuracy from an industry standard of +/- 0.002&#; down to +/- 0.&#;, including in the Z-axis, which makes these ideal for high-aspect ratio and controlled depth blind via drilling.
Finally, our lowest-end PCB drilling machines are Excellon Century drillers. All of these machines are equipped with automatic measurement systems that measure drill bit length, diameter, spindle runout, and broken drill bit detection. Essentially, these capabilities remove the human element from these drilling issues, thereby minimizing the chance of operator error.
PLATING (PTH)
Manual dip tanks.
Saturn employs two automatic electroplating lines with both DC and Reverse Pulse capabilities. Saturn has designed both lines with the intent to minimize plating variation, which is the main goal of production plating. This is accomplished by including the following:
1. Racks that only allow panels to be plated one-high.
2. Anode-to-anode distance is 28 in. (max. distance for plating).
3. Water-submerged positive cathode contact.
4. Chemical-submerged anode bars for positive contact.
5. Eductor system utilizes a high volume chemical flow instead of air to accomplish chemical agitation.
6. Mechanical agitation to allow chemical to flow through holes.
7. Vibration to remove air from microvias and blind microvias.
8. Dual-sided rectification equalizes Cu plating throughout racks.
9. Advanced rectifiers (2 per rack) with 0.5% max. ripple effect.
10. Panels are now being plated at 11 to 14 amps per square feet (ASF), versus an industry standard of 45 ASF. This will result in more uniform plating, albeit lowered production throughput.
11. High ductile plating meets C 1,000-hour cycle tests.
12. Chemistry has been revised so that high-aspect ratio plating can be performed. Both lines are calibrated to plate 10:1 aspect ratio as a standard.
Conveyor line capable of 7 mil line / spacing.
New Line Features:
1. Dual filtration system prevents debris from reaching nozzles.
2. Resist strip fully outfitted with Swell, Spray, High Pressure Resist Strip Spray, and High Pressure Water rinse. Ideal for fine line / HDI designs.
3. Etcher outfitted with vacuum etch bars to minimize top-to-bottom variation &#; measured to be within +/- 0.&#;.
4. Line Speed 2 meters / minute for 1 ounce (>3x output).
5. Outfitted with automation makes this a < 1 operator process.
LPI SOLDERMASK
Manual tables or AutoRoll machines.
Saturn employs the use of three Argus spray coating lines, which deposit less soldermask within holes and eliminate dimple marks on the board surface.
Furthermore, this process results in a much more uniform soldermask thickness across the product surface area, making it an ideal solution for heavy copper PCBs.
LPI IMAGE
Customer artwork is aligned manually by eyeballing the registration of the film to the drilled panel.
Automated Registration: Saturn has purchased and installed three Olec AT-30 automatic alignment exposure units. These units use four cameras to align artwork top to bottom, and then use panel motion systems to automatically adjust the panel position to a best fit to the artwork. Furthermore, these units have hybrid-collimated light units that ensure exposure light attacks the panel at 90 degree angles to the artwork, which is critical for fine feature resolution.
FINAL BAKING
Manual convection box ovens.
Link to Shenzhen Thriver Digital Tech Co., Ltd.
Saturn has installed a Bassi Tunnel oven to perform final baking.
Since heat is uniformly applied to the boards and the machine controls the cycle time, quality is improved dramatically.
POST-HASL CLEANING LINE
LPI Cleaning line is also used as a post-cleaner.
Standard unit has two 1/2" wide brushes; one 1/2 H.P. chemical and water pumps; 1/2 gallon per minute nozzles.
All PVC, allowing max constant operating temperature of 120° to 130° C.
Industry standard Post-HASL Cleaning Line contains four chambers.
Saturn designed and built a custom post-HASL cleaning line for the sole purpose of removing the flux from the board's surface.
This high-pressure, high-temperature post-cleaner is made entirely of stainless steel allowing it to run at 150°F. Unit can spray regular and D.I. water at 1 to 1.5 gallons per minute at 50 psi using 7.5 HP pumps (1/2 gallon per minute, 20-30 p.s.i., 1.5 HP is the best available on the market).
Furthermore, the cleaner uses 8-1&#; wide toothbrush-type agitating brushes versus an industry best of 4-0.5&#; brushes. This custom process has been proven to remove ionic contamination from the surface of PCBs to well below industry standards.
ELECTRICAL TEST
Either clam shell tester or single flying probe.
Saturn has eight Mania double-sided, double-density grid testing machines. The fixture cost for these testers is half the cost or less than those used in more traditional clam shell testers since we build everything in-house.
We also utilize nine flying probe testers for smaller and prototype orders. This allows the customer to forego the cost of a hard testing fixture in favor of a modest testing fee.
CLEANING (Routing)
Washer using city water.
Saturn has installed a washer in its shipping department that uses de-ionized (D.I.) water to achieve bare board cleanliness.
D.I. water results in a cleaner board; more importantly, it further removes ionic contamination that may have occurred after HASL.
DUPLICATE PROCESS
Due to cost and/or space constraints, many PCB shops will not have duplicate processes.
All of Saturn&#;s processes incorporate duplicate equipment so that in the case of an equipment failure, Saturn&#;s production capabilities will not be compromised.
We also provide contingency by serving as a critical resource to customers on the verge of experiencing line shutdowns due to supply chain gaps prior to product launch or offshore supply chain disruptions.
ADVANCED CAPABILITIES
Minimal / Outsourced
In-house capabilities include laser drilling, laser routing, PTFE plasma preparation, Plasma treatment and etchback.
We also offer fine lines and spacing, controlled impedance, heavy copper, high-voltage, PTFE for RFMW, open and internal cavities, thermal management, heatsinks, HDI, blind and buried vias, via-in-pad, edge plating castellations, semi-flex, rigid-flex and flexible circuits.
SURFACE FINISHES
HASL, others outsourced
Measure the characteristics of our Surface Finishes by reviewing this comparison charts Here is a quick list of the final finishes provided in-house (automated processes in orange):
SnPb HASL
OSP
Immersion Silver
Immersion Gold
Immersion Tin
Electrolytic Hard and Soft Gold
QUALITY CERTIFICATIONS
No certification is viewed as standard.
Saturn is certified for the following quality specifications:
FINANCIAL
No standards available.
Saturn is extremely conservative financially. Keeping the company healthy is our top priority over shareholder distributions. SEC has remained debt-free for 35-years.
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