Sample Test Reports for efficient registration error analysis and PCB manufacturing process control

Quantifying different causes of registration errors is the key to effective registration process control. Separating Causes

Tracking PCB construction variables

Enhanced PerfecTest coupon measurements The basis to identify and quantify registration errors and their causes Largest registration error on this panel. Automatically calculated after test data was collected from PerfecTest coupons Test results from one panel

Fluctuation of Errors on different panels indicate RANDOM SHIFT ERROR MAXIMUM TRUE POSITION ERRORS Largest registration error per panel Biggest registration error by panel

Identify, separate & correct EXPANSION ERRORS occur when inadequate scaling factors are applied to the artwork. Expansion registration errors are job specific. They describe the size of layers of a specific job. Depending on materials, panel constructions, and fabrication processes, necessary scaling factors will differ with each job. SHIFT ERRORS describe the location of inner layers, cores, or panels during the fabrication process. Shift errors are caused by tooling inaccuracies or operator errors. Shift error patterns are typically repeated on different jobs. Expansion errors are corrected with better scaling factors. Shift errors are corrected with tooling adjustments and improved operating procedures.

Nominal size Actual size Illustration 2Illustration 1 Actual size Nominal size -.005” -.007”-,003” Shift targets Total registration error: -.005” ” = -.010” negative expansion error only corrected with scaling. Maximum error is 0.005”. Total registration error: -.007” ” = -.010” combination of shrinkage & shift error corrected with scaling & process adjustments. Maximum error is 0.007”. Nominal Location.002 shift in +X axis SIZE and SHIFT illustration

Expansion error by layer, Averages of 6 panels Average Expansion errors

Corrected scaling factors -automatically calculated- adjust for irregular expansion. NOTE: Scaling artwork will ONLY correct for expansion & shrinkage errors. Repetitive and random shift errors require tooling, process, or operator adjustments. Corrected scaling

Shift errors averaged over the production lot indicate layer, core, and panel repetitive offset errors To determine random shift errors refer to individual panel data Average shift errors

Expansion errors and maximum true position errors are calculated from coupon measurements in Sites 1, 2, 3, 4. Shift errors are determined by the cross points of the diagonals from Site 1 to Site 3 & Site 2 to Site 4 Site 4 Site 3 Site 1Site 2 Shift target Maximum True Position Error by layer Calculating expansion & shift errors

Red dots illustrate the average of layers in panel 1 Green dots illustrate the average of layers in panel 2 Blue dots illustrate the average of layers in panel 3 Grey dots illustrate the average of layers in panel 4 Dark green dots illustrate the average of layers in panel 5 Purple dots illustrate the average of layers in panel 6 Average registration errors by panel

Different locations of average shift targets, indicate shift of panels during drilling. scattered dots indicate random drilling process errors overlapping dots indicate drill offsets a combination of random and offset drill errors occurs frequently Shift targets Random & repetitive drilling shift errors

Inner layer averages from 11 panels in a production lot Average inner layer registration

Averages from 11 panels of a production lot with multiple lamination cycles Comparison of inner layer cores All inner layers Layers 2 & 9 added in second lamination cycle. Lamination shift registration errors

Random shift on panels from the same production lot. Compare lamination and drilling shifts.

Random rotation of the same inner layer cores on different panels. Random shift of inner layers and inner layer cores on different panels of the same production lot. Rotation & shift in - X Rotation & shift in –x & +y Inner layer 3 Inner layer 4 Lamination random shift errors

A fully integrated solution to match registration challenges Predict scaling for new jobs

Factory Integration Availability of precise registration data when it is needed & where it is needed. Easy importation of precise or best-match scaling data when new jobs are being configured. View & analyze Registration data On workstations Automatic New job setup On workstations Direct or remote New job setup on workstations Automation Script PerfecTest System