Saturn Electronics Corporation is a leading printed circuit board fabricator that offers high-volume production and quick-turn prototype boards. It has strong financials with no debt and fully paid buildings and equipment. It owns three fabrication facilities in the US to enhance purchasing power and safeguard production. Saturn serves industries such as aerospace, automotive, defense, medical, and telecommunications with delivery times ranging from one day to three weeks. It has attained several certifications including AS9100, ISO9000, and ISO14001.
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PCB Manufacturer, Domestic Circuit Board Production and Prototype
5. GROWTH & FINANCIAL STRENGTH
Production & Prototype
Saturn Electronics Corporation, is a Top 30 domestic PWB Fabricator managing the nuances between
Quick-Turn Prototype Boards and High-Volume PCB Production while offering industry-leading Lead
Free circuit boards that meet RoHS compliance.
Financial Strength
Saturn Electronics Corporation keeps bank debt at a zero balance. Our building and equipment are
fully paid. Our financial strength has resulted in relationships with the largest suppliers in our industry-
- as we are able to meet their latest demands through the continuous reinvestment of technologically-
advanced equipment.
Growth
Saturn Electronics Corporation owns controlling interests in three PCB facilities (Chicago, Pittsburgh,
and Atlanta), which enhances purchasing power and safeguards production.
Industries Served
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 one day to three weeks. We have provided solutions for the following industries:
l Aerospace
l Automotive
l Defense
l Gaming
l High-Precision Scales
l Gaming
l Membrane Switches
l Medical
l RF-Microwave
l Telecommunications
Company Contacts
Nagji Sutariya President/QC Manager . . . . . . . . . . . . Nsutariya@saturnelectronics.com
Ishvar Sutariya VP Operations . . . . . . . . . . . . . . . . . . . Ishvar@saturnelectronics.com
Perry Sutariya VP Sales . . . . . . . . . . . . . . . . . . . . . . . Perry@saturnelectronics.com
Yash Sutariya VP Corporate Strategy . . . . . . . . . . . . Ysutariya@saturnelectronics.com
Syed Salam Customer Service . . . . . . . . . . . . . . . . Syed@saturnelectronics.com
6. C E R T I F I C AT I O N
AS9100
Saturn was one of the first PCB Fabricators to attain AS9100 Certification.
ITAR
Saturn recently became a registered ITAR PCB Manufacturer ensuring that documentation, training
and proper procedures are employed in the handling, use, and transfer of sensitive information com-
plies with the Arms Export Control Act (AECA).
ISO9000 & TS16949
Saturn was the first printed circuit board manufacturer in North America to achieve TS16949, which is
a world-wide quality standard that replaced QS9000 in 2006.
ISO 14001:Environmental
This Certification states that Saturn Electronics Corporation complies with the requirements of BS EN
ISO 14001:2004 for the scope of Manufacturer of PC Boards for Automotive, Commercial, and Heavy
Equipment Industry.
MBE
Saturn is a Minority Business Enterprise certified with the Michigan Minority Business Development
Council as defined by the National Minority Business Development Council for NAICS Code 334412,
bare printed circuit board manufacturing.
7. OFFSHORE SOURCING
Supply Chain Management
In order to be a full service supplier to our customers, we also offer offshore sourcing for higher volume projects where
cost constraints prevent domestic manufacture. We take pride in that we offer a great deal more value add than traditional
overseas brokers, and even other domestic PCB fabricators offering the same services. Below is a table outlining just a
few of these benefits.
Materials
Saturn Competitors
Production/TS16949 Certified Domestic Facility as Many don’t even have a facility, just an office and/or
backup. warehouse. Those with facilities are not production/
TS16949 certified.
We audit and approve our suppliers in person per Many have not even visited their suppliers. Those that
TS16949 audit procedures. have aren’t certified themselves to audit to particular
standards.
Offshore product is shipped out to customers under our The vast majority of our competitors lack this certification.
TS16949 flag.
All product is automotive certified, regardless of end use. ???
Saturn guarantees all offshore product with our No published guarantee matches Saturn’s.
unmatched 5x guarantee.
Saturn has personnel on-site in Asia to oversee our and Majority do not have any staff whatsoever in Asia.
our customers’ interests.
Saturn performs all engineering work domestically prior
to sending files for offshore manufacture. This ensures ???
customers’ requirements are properly communicated.
Saturn will keep inventory at Romulus, MI and ship to Customer is required to purchase and take delivery on
releases. entire quoted quantity.
8. P R O D U C T I O N C A PA B I L I T I E S
Technology Roadmap
Our technological capability is totally customer driven. The following roadmap does not project bryond 2008 because it
can change at any time.
Materials
Features Current Capability Future Capability 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”
Fabrication
Features Current Capability Future Capability Today’s Products
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
Imaging
Features Current Capability Future Capability Today’s Products
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”
Plating & Surface Finishes
Features Current Capability Future Capability Today’s Products
Finished Copper Thickness 20 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
10. Industry Standard Saturn Electronics
Saturn Electronics Corporation 28450 Northline Rd., Romulus, MI 48174 (734) 941-8100 Fax (734) 941-3707
Process Description
BUYERS GUIDE
1 Copper Laminate (base Standard sheet sizes that are Standard panel sizes with saw-cut edges.
material) sheared to size in-house.
This significantly reduces contamination in subsequent processes (e.g., imag-
ing, testing, etc.)
2 Drilling Drilling machine that requires tools Saturn’s lowest-end drilling machines are Excellon System 2000 and Century
to be changed manually. Maximum 2001 CNC drillers. All of these machines are equipped with automatic mea-
panel sizes are typically 18” x 24”. surement systems that measure drill bit length, diameter, spindle runout, and
No control in Z-axis, +/- 0.002” hole broken drill bit detection. Essentially, these capabilities remove the human
position accuracy/ element from these drilling issues, thereby minimizing the chance of operator
error.
Saturn also has three Mania Micronics 86 drilling machines. These machines
incorporate the industry’s latest linear motion technology and 180k RPM high
speed spindles. The use of linear motion increasing hole position accuracy
from an industry standard of +/- 0.002” down to +/- 0.0005”, including in the
Z-axis, which makes these ideal for controlled depth blind via drilling.
3 Image Room Enclosed room. Saturn has a Class 10,000 Clean Room.
The environment in this room minimizes foreign material from creating com-
mon shorts in the imaging process. Also, strict temperature and humidity
controls prevent distortion in the customer artwork.
4 Imaging / Exposure Customer artwork is aligned manu- Standard: Saturn uses MultiLine equipped drawers for imaging. MultiLine
ally by eyeballing the registration of tooling removes the human factor involved in lining up the bottom film to the
the film to the drilled panel. top film. This results in significantly reduced off-registration issues.
Light source is a single point light Advanced (inner layers): Saturn also employs the use of an Olec AX-28
source, making it not possible to use automatic exposure unit that uses two cameras to align the top and bottom
on fine line images run on production artwork. This machine can hold registration as tight as +/- .0005 mils front to
panel sizes. back for inner layers.
Industry-Leading (inner and outer layers): 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 expo-
sure light attacks the panel at 90 degree angles to the artwork, which is critical
for fine line resolutions.
5 Plating Through Holes Manual dip tanks. Saturn employs two automatic electroplating lines and, as such, PTH is a two-
(PTH) step process. Saturn has built a custom automatic plating line that has been
designed and constructed primarily in-house. The intent was to minimize plat-
ing variation, which is the main goal of production plating. This was accom-
plished 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 highvolume chemical flow parallel to the pan-
els 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 to equalize copper plating from one side of the rack
to the other.
9.State-of-the-art rectifiers (two per rack) with 0.5% maximum ripple effect.
10. Panels are now being plated at 15 amps per square feet (ASF), versus
an industry standard of 45 ASF. This will result in more uniform plating, albeit
lowered production.
11. High ductile plating process that meets C7000 specs for 1,000 hour cycle
tests.
12. Chemistry has been revised so that high-aspect ratio plating can be per-
formed. Both lines are calibrated to plate 10:1 aspect ratio as a standard.
6 Strip-Etch-Strip Conveyorized line that is capable of In 2008, Saturn installed a new Hollmuller SES line. This line incorporates
producing 7 mil line/spacing. the latest in spray technology that minimizes chemical puddling. This is line
capable to accurately and uniformly etch down to 2 mil lines and spaces.
7 Cleaning prior to LPI Manual dip tanks or small conveyor- Instead of using a chemical cleaning process that may increase ionic contami-
ized chemical cleaning line. nation and compromise the surface finish, Saturn utilizes an Aluminum Oxide
Jet Scrubber. This process uses an aluminum oxide slurry that is sprayed on
the panels to remove copper oxidation.
8 Liquid Photo-Imageable Manual tables or AutoRoll machines. Saturn uses 2 DP- model LPI applicators to be used in lieu of AutoRoll solder-
Soldermask mask applicators.
For standard colors, Saturn also employs the use of two Argus spray coating
lines. This will result in less soldermask within holes and eliminates dimple
marks on the board surface. Furthermore, they will result in a much more
uniform soldermask thickness across the product surface area.
www.saturnelectronics.com
11. Process Description Industry Standard Saturn Electronics
9 LPI Image Customer artwork is aligned manu- Standard: Saturn uses MultiLine equipped drawers for imaging. MultiLine tool-
ally by eyeballing the registration of ing removes the human factor involved in lining up the bottom film to the top
the film to the drilled panel. film. This results in significantly reduced off-registration issues.
Industry-Leading (inner and outer layers): 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. Further-
more, 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.
BUYERS GUIDE
10 LPI Developing Standard conveyor that is separated Saturn has conveyorized the developing, final baking, and cleaning processes
from baking and cleaning lines. into a single production line. This should improve quality through reduced
handling and utilizing higher-end machinery.
Our developing line is constructed of a single-chamber, stainless steel devel-
oping line.
11 Final Baking Manual convection box ovens 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, qual-
ity is improved dramatically.
12 Cleaning Manual dip tanks. Saturn installed a Hollmuller conveyorized cleaning line in 2009, in line with the
other major wet process upgrades we have made since 2007.
13 Hot Air Solder Leveling Vertical SnPb HASL. Pb-Free HASL Saturn has installed three Lantronics TT-30 vertical hot air levelers. These ma-
(HASL) typically outsourced. chines were designed with the intent of using this finish on finer pitch devices
than in the past. They hold the panels at 45° angles so that SMT pads are not
at 90° or 180° angles to the air knives.
Saturn uses two of these units for SnPb HASL, and the third for Nihon Superi-
or’s SN100CL lead-free solder finish process.
14 HASL Post-cleaner LPI Cleaning line is also used as a Saturn has custom fabricated a high-pressure, high-temperature post-cleaner
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 psi, 1.5 HP is the best available on the market). Fur-
thermore, 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 using Saturn augments its visual inspection process by utilizing automated optical
a light table. 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 single fly- Saturn offers a variety of testing alternatives. First, Saturn has 5 Mania double-
ing probe. 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.
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, in-
stead, pay a modest testing fee.
Saturn Electronics Corporation 28450 Northline Rd., Romulus, MI 48174 (734) 941-8100 Fax (734) 941-3707
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 PCB All of Saturn’s processes incorporate duplicate equipment so that in the case
shops will not have duplicate pro- of an equipment failure, Saturn’s production capabilities will not be compro-
cesses. mised.
Furthermore, Saturn has controlling interests in three other domestic PCB fab-
rication 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 prepa-
ration, Plasma treatment and etchback, and special project groups to assist
customers with critical and technologically demanding products.
20 Minimum Hole Size .015” .002”
21 Minimum Line/Spacing .007” / .007” .003” / .003”
22 Surface Finishes HASL HASL; Lead-Free HASL; Immersion Silver, Immersion Gold
23 Quality Certification No certification is viewed as stan- ISO 9000, TS16949, Delphi C7000, ISO14000; AS9100
dard.
24 Financial Liabilities No standards available. $ 0 Bank Debt
$ 0 Accounts Payable
$ 0 Lease obligations
www.saturnelectronics.com
12. HOW SATURN DISTINGUISHES ITSELF FROM COMPETITORS
Our commitment to quality allows us to offer our unmatched product guarantee of up to 5 times the cost of
the PCB to cover components and labor applied to products with opens or shorts!
CORPORATE PCB CERTIFICATIONS
$ 26 Million Annual Sales TS16949
Debt-Free PCB Manufacturer ISO9001:2000
Board Manufacturing History AS9100
PWB Technology Roadmap ISO14001
IPC-1710-A Minority Business Certification
PCB Fabrication Flowchart ITAR Certification
Corporate Presentation UL USA Certification
UL Canada Certification
PRODUCTS / CAPABILITIES PCB FAB SERVICES
Up to 24 Layers Quick-Turn Prototype PCB
3 mil line / space Quick-Turn PCB Production
Heavy Copper PCB Small-High Volume PCB Production
Thermal Management Board Certified Offshore PCB Sourcing
Blind / Buried Vias
Open Cavity PCB
Internal Cavity Board
PTFE / RF-Microwave Board
28450 Northline Rd., Romulus, MI 48174
Phone: (734) 941-8100 Fax: (734) 941-3707
www.saturnelectronics.com
Certified MBE
(Minority Business Enterprise)