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PCB Fabrication Manufacturer Corporate Brochure


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Corporate brochure for Saturn Electronics Corporation featuring PCB Manufacturing Equipment, advanced technologies, IPC standards and industry certifications. PCB Buyer's Guide included for industry comparisons.

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PCB Fabrication Manufacturer Corporate Brochure

  1. 1. G R OW T H & F I N A N C I A L ST R E N GT H / C U STO M E R BAS E G R OW T H & F I N A N C I A L ST R E N GT H Financially, Saturn is very strong. Our building and all of our equipment are fully paid. Saturn owns controlling interests in PCB facilities in Chicago, Cleveland, Pittsburgh, and Atlanta. Owning these other facilities improves our purchasing power, and provides a production safety net in case of a catastrophic event. Our financial strength also helps us to purchase new and technologically advanced equipment as the manufacturing market demands. Please visit our website for an updated equipment list. C U STO M E R BAS E We service a wide variety of customers with needs that vary from 5 pieces to tens of thousands of pieces. Our customers’ needs range from medium to fine line technology with delivery requirements from two weeks to two hours. Judge us by the company we keep: Delphi Automotive Systems (Automotive) Lear Automotive Systems (Automotive) Siemens VDO (Automotive) Rockwell Automation (Industrial Drives Controls) Telect (Telecommunications & Networking) 3Com (Telecommunications & Networking) Black Box Corporation (Telecommunications & Networking) Grand Products (Gaming) Celestica (Contract Manufacturing) Jabil (Contract Manufacturing) Tyco Electronics – M/A Com (Microwave Electronics) Memtron (Membrane Switches) Mettler Toledo (High-Precision Scales) CO M PA N Y CO N TACTS Nagji Sutariya – President/QC Manager . . . . . . . . . . . Ishvar Sutariya – VP Operations . . . . . . . . . . . . . . . . . Perry Sutariya – VP Sales . . . . . . . . . . . . . . . . . . . . . . . Yash Sutariya – VP Corporate Strategy . . . . . . . . . . . . Jay Fredericks – National Sales Manager . . . . . . . . . . Syed Salam – Customer Service . . . . . . . . . . . . . . . . . . Saturn Electronics Corporation 28450 Northline Rd. Romulus, MI 48174 734.941.8100 See reverse.
  2. 2. P R O D U CT I O N CA PA B I L I T I ES / T EC H N O LO GY R OA D M A P P R O D U CT I O N CA PA B I L I T I ES Our technological capability is totally customer driven. The following roadmap does not project beyond 2008 because it can change at any given time. M AT E R I A L S Feature Current Capability Future Capabilities Today’s Products Laminate Nominal Tg 260˚C 260˚C CEM-1 Laminate Nominal Td N/A 350˚C CEM-3 Maximum Layer Count 24 24 FR-4 Min Finished Thickness .014” .014” 170Tg FR4 Min. Core Thickness .005” .004” - .002” Lead Free Maximum Panel Size 18” X 24” 20” X 24” FA B R I CAT I O N Feature Current Capability Future Capabilities Today’s Product Minimum finished hole size .006” .006” Drilling Blind/Buried Vias .006” .003” - .002” Routing Routed Part Tolerance +/-.005” +/-.005” Scoring Scoring Tolerances +/-.003” +/-.003” Punching I M AG I N G Feature Current Capability Future Capabilities Today’s Product Minimum Lines/Spaces .004” .003”-.002” Photo Print Min. Quad Flat Pack Pitch .016” .016”-.012” Plugged Hole Minimum Pad Size .005”/side .005”/side-.004”/side Peelable Mask Soldermask Registration .003” .002” Soldermask Tolerance .002” .002” P L AT I N G & S U R FAC E F I N I S H ES Feature Current Capability Future Capability Today’s Product Finished Copper Thickness 12 ounce Selective Finishes Hot Air Solder Leveling Yes RoHS Compliant Lead-Free Solder (HAL) Yes Heavy Cu Full Body Hard Ni/AU Yes Multilayer Immersion Gold/Silver Yes
  3. 3. E X A M P L ES O F C U R R E N T T EC H N O LO GY A P P L I CAT I O N S The exciting part of the Printed Circuit Board fabrication business is the integration and application of various fabrication processes for the manufacture of high technology, exotic, and other non-standard products. Here are just a few of the many examples we have at Saturn. Fine Line and Spacing We have invested over $200,000 in software, analysis tools, R&D, and equipment to develop systems for fine line and spacing products. The current system addresses layer to layer registration issues by customizing material scale factors for each specific design. Also, we use a cupric etching system, which is essential for creating fine lines on inner layers. As a result, we are currently processing 3 mil line / spacing in prototype quantities (4 mils in production) and have built boards with layer counts in excess of 20 layers! Controlled Impedance Designs Our engineers have access to impedance design and stackup software that enables us to verify your line widths, spacing, and stackup prior to CAM. Based on the proximity of your design to our calculations, we can make adjustments to the design or adjust the stackup to best model the desired impedance. After fabrication, we verify our calculations by performing impedance testing using our Polar CITS500s Controlled Impedance Test System. Heavy Copper Multilayer At one point in recent history, Saturn was one of North America’s largest users of heavy copper laminate, which we used in the production of power distribution boards for the automotive industry. We retained our skill set in precision etching heavy copper and applied it to other industries, namely the power supply industry. Furthermore, we applied our registration system to address concerns such as layer to layer winding registra- tion, dry resin, and etch factors commonly seen by users of heavy copper multilayer boards. We commonly produce boards with 2, 3, 4, & 6 ounce copper with up to 20 layers! PTFE / Hybrid Technologies The addition of the March plasma treatment system allows us to offer our customers PTFE (or Teflon) based products. These are commonly used in designs with signal integrity concerns. Standard PCB fabricators cannot offer these materials easily due to the plasma treatment these materials typically require. In order to plate this material effectively, the surface must first be activated. We have in-house capability and materials inventory that enables us to best serve our customers. We have also developed the proper lamination recipes that are required to produce hybrid boards using PTFE-based and FR-4 materials together in one design. Cavity Boards Cavity boards are multilayer designs that expose inner layers to air by requiring pockets of material to be cut out. This requires laminating precut materials, controlled-depth fabrication, tight processing controls, and manufacturing versatility. Also, our standardized Multi-Line tooling systems have been critical in the process- ing of cavity boards. Internal-Cavity Boards Internal-Cavity boards are multilayer designs that require air gaps in internal layers. Again, this requires laminating precut materials, tight processing controls, manufacturing versatility, and standardized Multi-Line tooling systems to manufacture cost-effectively in volume quantities. Saturn Electronics Corporation 28450 Northline Rd. Romulus, MI 48174 734.941.8100 See reverse.
  4. 4. Q UA L I T Y SYST E M S Q UA L I T Y SYST E M S In order to deliver the highest quality products to our customers, we have implemented several quality Assurance and Continuous Improvement systems. Our primary goal is to maintain a robust quality system that emphasizes defect prevention and reduction of waste in the supply chain. Some of the salient features of our Continuous Improvement systems are as follows: Quality & Reliability Testing To ensure our customers receive product that is of world-class quality, we utilize inside and outside testing capabilities. On a daily basis we manufacture a test panel that includes all of our capabilities. Once it is complete, we steam age the panel for 8 hours, test for solder ability, cross section all the hole sizes to verify plating quality, and then test for Ionic Contamination. This is done on a daily basis, but every year we fabricate a daisy chain test panel and send it out for High Temperature Storage (125∞C), Temperature Cycling (-45 C - 125 C, 1000hrs.), and High Humidity (100%, 1000 hrs.). These samples must maintain less than 10% resistance and then they are micro sectioned to verify the visual characteristics. In addition to these tests, we perform extensive Ionic Contamination tests, solder ability tests, resistance to chemical tests, and Autoclave. Quality Circles: Saturn uses quality circles to find ways to improve each production process within the plant. A team of people assembles in each area of production (not necessarily their own) and they look for areas for improvement. Brainstorming meetings are held and all feasible changes are implemented. This program allows operators to contribute towards continuous improvement programs, while gaining knowledge about other processes other than their own. Kaizen: Kaizen means continuous improvement in Japanese. Utilizing Kaizen in our processes has helped us to improve our process efficiency by eliminating waste and unnecessary motion within the manufacturing process. Internal Quality Audits: Saturn has an Internal Audit system in place, which audits all key elements of our business quality manage- ment system every three months. The system verifies whether quality activities comply with planned arrangements, and it also determines the effectiveness of the quality system. A group of trained personnel are assigned to conduct these audits. Continuous Employee Certification Program: Saturn employees are not authorized to work on their own until they pass a certification program for each process in which they are involved. All employees undergo retraining and recertification every six months. Zero defect areas: Drilling, Routing, Scoring, Image, Electro-plating, Etching, and First Article Inspection are declared as zero defect areas. A zero-defect area is a process in which a single non-conformance must be investigated to find the source of the problem and a permanent action will be taken to prevent it from reoccurring.
  5. 5. Q UA L I T Y ASS U RA N C E Q UA L I T Y ASS U RA N C E High Reliability Certification In our quest to attain industry-high quality, we came across a leading automotive electronic supplier’s certification program. The certification process requires the PCB to pass a battery of tests and to meet strict product specifications that address forward-looking industry concerns. One example of the tests is a thermo cycling test, which is meant to simulate a PCB in the field over time under the most extreme of conditions. The test includes 1,000 cycles, each of which takes one hour. During each hour, the PCB is taken from room temperature to -40°C in 5 minutes. The PCB remains at that temperature for 25 minutes, and is then taken to 125°C within 5 minutes. The PCB is then kept at this temperature for 25 minutes, after which it is brought back to -45°C within 5 minutes. After 1,000 cycles, the PCBs must maintain less than 10% resistance in order to pass. Only PCB fabricators with the most reliable of plating lines are able to pass this test. In addition to this test, this customer performs extensive high temperature storage, steady state humidity, surface ionic contamination, flammability, solder ability, resistance to chemical, and autoclave tests. We at Saturn are proud to say that our process has been High Reliability certified since 1999. The benefit to our customers is that 100% of our products are run through this High Reliability certified process! ISO 9000:2000 / TS16949 The goal for ISO 9002 is the development of fundamental quality systems that provide for continuous improvement, emphasizing defect prevention, and the reduction of variation and waste in the supply chain. The key elements of ISO 9002 include documentation of all processes, Failure Mode Effective Analysis (FMEA), Quality Control plans, Reaction plans and Statistical Process Controls. TS16949 extends significantly on ISO 9002 requirements by incorporating customer-specific requirements and determining the supplier’s ability to meet them. TS16949 is a global replacement for QS9000 in that it aligns existing US, German, French, Japanese, and Italian automotive quality standards. We are proud to say that Saturn is North America’s first Printed Circuit Board Manufacturer to achieve this worldwide recognized quality standard. In fact, as of January 2006, Saturn remains the only Printed Circuit Board manufacturer to have been awarded this certification. Saturn has been ISO 9002 certified since 1995 and TS16949 certified since 2003 and will continue to pursue further quality certifications. ISO14000 Our commitment to the environment is just as strong as our commitment to quality. As such, we pursued and were awarded ISO14000 certification in 2005. ISO14000 is a system dedicated to the reduction of waste in the process and issued to the environment. This system requires strict adherence to local and federal environmental regulations, recycling programs, and documented procedures. All of these activities result in a “greener” organization that is committed to social and environmental responsibility. AS9100 AS9100 defines additional areas within an aerospace quality management system that must be addressed when implementing an ISO9001:2000 based quality system. Typically, these requirements are included within robust aerospace quality systems. Saturn Electronics Corporation 28450 Northline Rd. Romulus, MI 48174 734.941.8100 See reverse.
  6. 6. C E RT I F I CAT I O N S Saturn Electronics Corporation 28450 Northline Rd. Romulus, MI 48174 734.941.8100 See reverse.
  7. 7. C E RT I F I CAT I O N S
  8. 8. M I N O R I T Y C E RT I F I CAT I O N
  9. 9. Process Description Industry Standard Saturn Electronics PCB Supplier 2 Top Score P C B 1. Copper Laminate Standard sheet sizes that are Standard panel sizes with saw-cut edges. (base material) sheared to size in-house. This significantly reduces contamination in subsequent B U Y E R ’S processes (e.g., imaging, testing, etc.) 2. Drilling Drilling machine that requires Saturn also has multiple Excellon Concept 4 and tools to be changed manually. Century 2001 drilling machines. These machines Maximum panel sizes are are equipped with larger table sizes that enable typically 18” x 24”. us to drill panels up to 20” x 28”. This will reduce handling per piece in subsequent processes. G U I D E Also, these machines are equipped with automatic measurement systems that measure drill bit length, diameter, spindle runout, controlled-depth capabili- ties, and broken drill bit detection. Essentially, these capabilities remove the human element from these drilling issues, thereby minimizing the chance of operator error. Furthermore, these are essential for producing high reliability microvias. 3. Image Room Enclosed room. Saturn has a Class 10,000 Clean Room. The environment in this room minimizes foreign material from creating common shorts in the imaging process. Also, strict temperature and humidity controls prevent distortion in the customer artwork. 4. Imaging / Exposure Customer artwork is aligned Saturn uses MultiLine equipped drawers for imaging. manually by eyeballing the MultiLine tooling removes the human factor involved registration of the film to the in lining up the bottom film to the top film. This results drilled panel. in significantly reduced off-registration issues. Saturn also employs the use of an Olec AX-28 auto- matic exposure unit that uses cameras to align the top and bottom artwork. This machine can hold registration as tight as +/- .0005 mils front to back. 5. Plating Through Manual dip tanks capable of Saturn has built a custom automatic plating line Holes (PTH) 5:1 aspect ratio or less. that has been designed and constructed primarily in-house. The intent was to minimize plating varia- tion, which is the main goal of production plating. This was accomplished by including the following: 1. It houses racks that only allow panels to be plated one-high. 2. Anode-to-anode distance is 28 inches (maximum allowable distance for plating). 3. Water-submerged positive cathode contact. 4. Chemical-submerged anode bars for positive contact. 5. Eductor system. This utilizes a high-volume chemical flow parallel to the panels instead of air to accomplish chemical agitation. 6. Mechanical agitation to allow chemical to flow through holes. P C B Saturn Electronics Corporation 28450 Northline Rd. Romulus, MI 48174 734.941.8100 7. Dual-sided rectification to equalize copper plating from one side of the rack to the other. 8. State-of-the-art rectifiers (two per rack) with 0.5% maximum ripple effect. B U Y E R ’S 9. Panels are now being plated at 17 amps per square feet (ASF), versus an industry standard of 30 ASF. This will result in more uniform plating, albeit lowered production. 10. High ductile plating process that meets C7000 specs for 1,000 hour cycle tests. G U I D E 11. 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. 6. Strip-Etch-Strip Conveyorized line that is Saturn has combined all three steps into one capable of producing 7 mil conveyorized line. Saturn is capable of producing line/spacing. 4 mil line/spacing in production quantities. 7. Cleaning prior to LPI Manual dip tanks or small Instead of using a chemical cleaning process that conveyorized chemical may increase ionic contamination and compromise cleaning line. the surface finish, Saturn utilizes a Pumice Scrubber to clean boards prior to LPI. This process uses a volcanic ash mixture and soft nylon brushes to remove copper oxidation. 8. Liquid Photo- Manual tables or AutoRoll Saturn uses 4 DP-model LPI applicators to be used Imageable Soldermask machines. in lieu of AutoRoll soldermask applicators. For stan- dard products, Saturn also employs the use of an Argus spray coating machine. This will result in less soldermask within holes and eliminates dimple marks on the board surface. 9. LPI Image Customer artwork is aligned Saturn uses MultiLine equipped drawers for imaging. manually by eyeballing the MultiLine tooling removes the human factor involved registration of the film to in lining up the bottom film to the top film. This the drilled panel. results in significantly reduced off-registration issues. Saturn also employs the use of an Olec AT-30 auto- matic exposure unit that uses cameras to align the top and bottom artwork. This machine can hold regis- tration as tight as +/- .0005 mils front to back.
  10. 10. Process Description Industry Standard Saturn Electronics PCB PCB Supplier 2 Top Score P C B Saturn Electronics Corporation 28450 Northline Rd. Romulus, MI 48174 734.941.8100 10. LPI Developing Standard conveyor that is Saturn has conveyorized the developing, final baking, separated from baking and and cleaning processes into a single production line. B U Y E R ’S cleaning lines. This should improve quality through reduced handling and utilizing higher-end machinery. Our developing line is constructed of a single-chamber, stainless steel developing line. 11. Final Baking Manual conventional ovens Saturn has installed a Bassi Tunnel oven to perform (usually Grieve model). final baking. Since heat is uniformly applied to the G U I D E boards and the machine controls the cycle time, quality is improved dramatically. 12. Cleaning Manual dip tanks. Saturn has a Chemcut XL547 conveyorized cleaning line. 13. Hot Air Solder Vertical HASL. Saturn uses Lantronix model TT30 hot air levelers Leveling (HASL) for both Tin-Lead and Lead-Free HAL. The TT30 was designed to hold panels at a 45º angle to allow these finishes to be used on higher density applications. 14. HASL Post-cleaner LPI Cleaning line is also used Saturn has custom fabricated a high-pressure, as a post-cleaner. high-temperature post-cleaner for use after the HASL process. This is a stainless steel post-cleaner unit that runs at 150˚F, sprays 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. 15. Inspection Visual inspection by personnel Saturn augments its visual inspection process by using a light table. utilizing visual inspection equipment. This equipment (hole checker) checks for holes that have been plugged by the HASL and LPI processes, incorrectly plated or non-plated holes, and drilled with incorrect drill bit sizes. 16. Electrical Testing Either clam shell tester or Saturn offers a variety of testing alternatives. single flying probe. First, Saturn has 5 Mania double-sided 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. Also, Saturn utilizes six flying probe testers for smaller and prototype orders. This allows the customer to forego the cost of a hard testing fixture and, instead, pay a modest testing fee. 17. Cleaning after Routing Washer using city water. Saturn has installed a washer in its shipping department that uses de-ionized (D.I.) water to clean the boards. D.I. water results in a cleaner board, but more importantly it further removes ionic contamination that may have occurred after HASL. 18. Duplicate Processes Due to cost constraints, many All of Saturn’s processes incorporate duplicate PCB shops will not have equipment so that in the case of an equipment duplicate processes. failure, Saturn’s production capabilities will not be compromised. Furthermore, Saturn has controlling interests in four other PCB facilities so that in the event of a catastrophic event, the supply chain will not be compromised. 19. Advanced Capabilities Minimal / Outsourced Saturn has grown from a technology standpoint exponentially since 2003. In-house capabilities include laser drilling, laser routing, PTFE plasma preparation, Plasma treatment and etchback, and special project groups to assist customers with crit- ical and technologically demanding products. 20. Minimum Hole Size .015” .002” 21. Minimum Line/Spacing .007” / .007” .003” / .003” HASL, Lead-Free HAL; Immersion Silver, ENIG 22. Surface Finishes HASL and Hard Gold 23. Quality Certification No Certification is viewed as ISO 9000, TS16949, Delphi C7000, ISO14000, standard AS 9100 24. Financial Liabilities No standards available $0 Bank Debt, $0 Accounts Payable, $0 Lease Obligations 28450 Northline Rd. Romulus, MI 48174 734.941.8100 734.941.3707 (Fax) Printed Circuit Board Manufacturers A P R O V E N L E A D E R I N Q U A L I T Y, R E L I A B I L I T Y A N D S E R V I C E