SERVICES & TECHNOLOGIES
The Technical Department task is to analyse the projects and provide all the possible support in case of documentation issues.
All the necessary tooling for manufacturing is prepared in this department (CNC routines, film artworks, …); the whole process is controlled via LAN in real time.
The Technical Department uses “UcamCo” and “Frontline” software for project files analysis and engineering; the files can be in “Gerber”, “ODB++”, “Sieb & Meyer” or “Excellon” format.
CUTTING AND DRILLING
Mechanical processes are done in this department; materials like FR4, IMS, PTFE (e.g. Diclad®) , polymide (e.g. Kapton® ) and Ceramic filled are used.
CNC drilling machines such “Posalux Mono” are available, that can drill up to 1.000 holes/min, equipped with spindles capable of 250.000 rpm.
On July 2017 the new "Posalux Trio CombiXY" CNC machine was installed.
It's a high technology equipment for drilling PCBs, provided with:
- 3 independent stations
- CCD cameras for registration
- contact drill system
- second measuring system for a perfect surface detection in controlled depth routing
- two different and alternating machining units per station (250.000 rpm for drilling, 60.000 rpm for routing)
- Automation for loading and unloading machined pieces, assuring 24/7 production.
This completes the range of Posalux machines in our drilling department, together with "Ultraspedd LZ3600" and "Mono".
ROUTING, SCORING, BEVELLING
According to the customer projects, I.C.S. can provide these processes for shaping the pcbs.
“Posalux Trio CombiXY” gets in the action when routing is required. Equipped with 3 independent stations, with 2 spindles for each station, can guarantee an exceptional routing accuracy; the other routing machine is “Posalux LZ 3600”, and both are capable to perform drilling routines too.
With metallisation, holes are prepared for the next copper plating process, which guarantee electrical conductivity between the various layers of the board. The process parameters are checked with multiple controls, on the same day too.
Desmearing is a chemical process which prepare holes for the next manufacturing step.
Through this line, the metallisation is reinforced with electroplated copper. The line, equipped with rectifiers with pulsed inverse current, is completely automatic and the operator controls it through a computer system to guarantee the best quality.
Etching consists in removing exceeding copper from the PCB layout.
Black Oxide is necessary on multilayer boards, to optimise the adhesion of “prepreg” material during lamination process.
AUTOMATED OPTICAL INSPECTION
AOI reveals defects on internal and external layers of each pcb.
LAYERS ALIGNMENT CONTROL
I.C.S. has an X-ray machine by Pluritec, that checks the alignment of laminated panels, to ensure an optimised drilling process.
The solder resist, is an acrylic-epoxy ink which is coated onto the pcbs to protect conductors from shorts during the soldering process, and esnure electrical insulation of the pcb.
This manufacturing step consists of the following phases:
- older resist is applied through a curtain coating machine, whose parameters are checked multiple times a day to guarantee correct solder resist thickness.
- Photoimaging and Developing
It's possible to print customer symbols and codes, through an inkjet legend machine.
The aim of peelable mask is to protect certain PCB areas from the wave soldering process.
Several finishings are offered by I.C.S:
- Lead Free Hot Air Levelling (“SACx” alloy)
- Hot Air Levlling
- Electroless Nichel/Gold
- Immersion Silver
- Immersion Tin
Electrical test is needed to check continuity and insulation of pcb nets. We can always track the testing of pcb batches, and a repair station is available. Pcbs that performed electrical test, are marked with a “TE” symbol.
I.C.S. has invested a lot in this area through the years, being now totally independent on this control phase. It has been the first italian company to get the flying probe test machine “ATG A7”, which uses 8 probes, high execution speed, 35x35µ as minimal testing pad and complete automation for loading and unloading pieces.
It checks if the final product complies with the customer requests and/or “Acceptability of Printed Boards” IPC-A-600 standard.
Conformity declaration is released on customer request, after every test is passed.