5 Effective Ways of Digital Image Correlation benefits in Lead-free PCB Manufacturing

By | Date posted: | Last updated: February 14, 2022
pcb-manufacturing

When it comes to manufacturing PCB manufacturing, reliability is a very important issue. The approach that works best is to proactively design it for reliability, instead of hoping that it works well, retrospectively. A whole lot of factors go into Making for reliability; a lot of it has to do with understanding how materials behave as well as interact with each other during the operational process. It is therefore important to study material characteristics such as Coefficient of Thermal Expansion or Transition Temperature. Selecting the wrong material can have a number of implications including but not limited to stress on the components and the joints.

An extremely useful tool to enable the process of reliability is Digital Image Correlation or DIC, as it is commonly referred to.

What this technique essentially does is that it proactively measures properties and provides a reliable value. So whether it is selection of material or test monitoring or simulation, you can be sure that you cannot go wrong! Digital Image Correlation or DIC is basically an optical method that can measure both displacements and deformation. In this method specimens are created with a contrasting speckle pattern. The specimen can then be tracked to see how it deforms. The advantage that it offers is that contact with the specimen is therefore not required. Also, DIC is able to produce full field displacement, which is not possible in other methods. DIC can also be performed with just a single camera. However in case if out of plane measurements are required, it needs multiple cameras. It can also be performed irrespective of the specimen size.

The technique has been growing in popularity in a whole lot of mechanical testing applications as it is easy to use. With computer technology and digital cameras showing a whole lot of technological advancements, the use of DIC is only slated to grow. DIC is therefore being extended to any imaging technology. It particularly finds a lot of use when it comes to Lead free PCB Manufacturing.

5 Reasons Why Digital Image Correlation is beneficial for Lead Free PCB:

1. Material properties

– DIC can be used to describe a whole lot of material properties like:

  • Young’s Modulus
  • Poisson’s Ratio
  • Coefficient of Thermal Expansion and more

It thus helps arrive at the best material to be used in case of PCB laminates. It can also help identify solder fatigue risks.

2. Test Monitoring

– Digital Image Correlation helps to study displacement and strain measurements. It can help monitor elements such as tensile and bending testing among others.

3. Warpage

– Often during reflow soldering, warpage is a concern. If there is a lot of warpage there are multiple issues such as interconnect formation, solder joint bridging and even the fear of component cracking. DIC can help identify the warpage and thus add to the reliability.

4. Finite Element Analysis (FEA)

– Through the use of DIC both input material properties as well as simulation results can be tested. Complex assemblies often see problematic strain regions. With FEA results this problem is significantly reduced.

5. Dynamic Applications

– Besides being used in static applications, DIC can also be used in dynamic applications such as vibration testing.

The benefits of DIC in lead free PCB manufacturing therefore cannot be over emphasized. With the use of this technique you can also rest assured that the PCB thus manufactured will live up to its reliability benchmarks.

Technotronix is one of the leading provider of Lead Free PCB manufacturing services to all the dominant industries. Having a strong manufacturing unit with a strong tool room and a team of experts, we are able to keep quality at the nucleus in each stage of PCB manufacturing. To get proper consultation or share your requirements to get a perfect PCB with cost effective strategy or to get a quote, drop an email to [email protected] or give a call @ 714/630-9200!

Methods Of Printed Circuit Board Recycling And Moral Codes Of Electronics

By | Date posted: | Last updated: April 19, 2023
pcb-recycling

With the changing customer preference and demand every other day, technology is blooming with a matured progress in the world of electronics. These electronic developments that have created magics in the quality of life for humans has only been possible due to advancement in printed circuit boards, becoming the core groundwork of every electronic system. In addition to the new innovation in every electrical system, the effective solution for the scrape, waste and unused electronics is creating a sensitive buzz and concern worldwide. This article is a technical trek that will help equip you with different methods of printed circuit board recycling. It brings forward the innovative concepts for PCB recycling treatments. To get insights into the techniques of recycling the waste printed circuit board and how it proves to be in favor of the environment, have a read!

It has become a sensitive concern to tackle the electronic scrap, electrical waste and unused electronics. The PCB fabricator and electronics manufacturers are now creating a new podium of PCB recycling. With this, one can get riches of multiple uses of various material and resources that are outcome of PCB recycling. Understanding the primitive, direct and advanced PCB recycling methods will make it easier to select the exact technique that can prove effective and cost savvy. TechnoTronix team provides PCB services for Renewable Energy printed circuit board prototyping.

There are various methods to recycle the printed circuit board. The direct techniques include landfills and incineration while the primitive recycling techniques consist of the Hydrometallurgy, Pyrometallurgy, complete recovery of non metallic fraction and Biometallurgy methods. Further researches have come up with the advanced PCB recycling technologies.

The extracts of value metal and components is a primitive technology to recycle the circuit boards. This accounts for heating the cables to extract the copper with evaporation of the unwanted resource. Another method that is well practiced since the past decade is the incinerator hazardous and leaching of chemical and heavy metals into the landfills.

The highly used PCB recycling methods that help recover precious metal scrap, electronic components, PCB’s and connectors are Electro chemical, mechanical shredding, Hydro-metallurgy and smelting process. By smelting and striping option, the ferrous metal, large & small structural metal parts, wires, heat sinks, cables, non ferrous metal scrap, ceramic and ferrite components are recovered. With innovation and technology driven methods, it is even possible to recover the hazardous wastes like mercury switches, CFC, CRT, flame retardant plastic, capacitor and batteries.

The Printed Circuit Board Recycling That Is Practiced Globally :

  • The precise method to treat the metal fractions is the biotechnological, Hydrometallurgy or the Pyrometallurgy process that is well defined by the mechanical shredding, Hydrometallurgy and physical separation from the circuit board. Firstly the pre-treatment process consist of disassembling the toxic and reusable parts with segregating the PCB. Secondly the Physical separation is done with the help of magnetic separators, electrostatic , eddy current and other methods. The Gasification and Pyrolysis is then performed as a part of chemical recycling to get precious metal components.
  • Other effective PCB recycling method that recovers the precious metals is the combination of the Smelting, Electrolysis and Hydrometallurgy. In this, the Smelting takes place with treating the connectors, processors, PCB’s and IC’s with the precious metal smelter and integrated copper. Here the Smelting takes place without reducing the size of circuit base. The required metal is then refined without reduction in the quantity. In addition to this, the Electrometallurgy, Pyrometallurgy and Hydrometallurgy process extracts the precious metals from the cores.
  • The well developed technology for reuse and recycling of electronic waste also proves efficient with the process of pulverization, chemical leaching and physical separation process. The combinations that are used to recycle the printed circuit boards also involve Depopulation, Calciner and Pyrolysis technique.

Scrutinizing the PCB Recycling process that best suits your project:

Process 1

  • Dismantling and Segregation: The electronic product is segregated into spare parts and further Dismantling it into PCB’s.
  • The populated PCB is converted into pulverized one and then physical separation is carried out with gravity or magnetic or electrical process.
  • The derived rich metal powder that consists of Cu, Au Ag, Pd metal fractions which is then individually separated with the help of chemical leaching process.

Process 2

  • The PCB is depopulated into PCB components and then is treated with the process of Pyrolysis that separates the Oil, Solid and Gasious substance.
  • This derives the materials with the help of Smelting and Calcination process.
  • The Metals are recovered by further processing the materials into the Electrolysis and Chemical leaching treatment.

The PCB recycling methods are many that are derived from an effective combination of innovative technologies that has and are taking a step ahead in preserving the environment. The PCB manufacturers, researchers are heading towards coming up with more Eco-friendly concepts to recycle the printed circuit boards and electronic scrap that can help reuse the precious metal, parts and chemicals without polluting the environment at large.

With having a combined extensive year of experience in PCB Manufacturing services, TechnoTronix has created a strong customer base for varied industries to shape up new trends for the electronic manufacturers across the globe. In addition to catering to these PCB services, TechnoTronix also has achieved specialization in PCB recycling with the help of a skilled team of experts. To get a consultation on PCB recycling and to understand the method that best suits your project, why not call us at 714/630-9200? In order to inbox us your queries or to ask for quotation, you can simply drop us an email to [email protected].

How To Avoid Common Problems With Gerber File During PCB Manufacturing Process

By | Date posted: | Last updated: April 8, 2022
pcb manufacturing

Printed Circuit boards vary in size and composition depending on their application. From basic PCBs used in standard applications to highly complex PCB configurations used in advanced applications, PCB designers are under constant pressure to design highly innovative yet efficient and functional PCB’s that can get the job done faster, better and easier. Leading edge applications like satellite guidance systems or even advanced automation systems require even more innovative PCB solutions to keep up with technological evolution in other controls. But irrespective of whether the pcb layout is simple or complex, the design phase typically ends with a series of Gerber files that serve as input for PCB manufacturer during the manufacturing and fabrication process. Gerber files can be defined as PCB blueprints in digital format used in the layer by layer manufacturing and fabrication of Printed Circuit Boards. A big part of the quality process in the manufacturing of Printed Circuit Board’s involves ensuring the Gerber files are exact and complete. Incorrect or incomplete Gerber files can result in the manufacture of faulty or non-performing PCB’s.  There are multiple Gerber files that get generated for every Printed circuit board and ensuring that each one of them is not only complete but accurate as well is critical in ensuring the end product is able to perform as per specifications.

There are many errors that can occur during the creation of Gerber files, some of the more common ones include:

Missing or incomplete Gerber files

Not all Gerber files created for the same PCB are equal in size and specifications. For instance an Excellon Gerber drill file contains specifications regarding the location and size of the holes, plated and unplated to be drilled in each PCB layer.  Each Excellon Gerber file needs to be complete along with the ASCII code and the tool number to be use for hole drilling for that particular layer. A single missing detail can change the entire configuration of the PCB by changing the size, shape or location of the hole on the board, which is why it is important to ensure that there are no incomplete or missing Gerber files.

Missing Aperture List

The basic purpose of an aperture list is to provide details regarding the kind and location of the tool to be used at each stage of the PCB manufacturing and fabrication process. When multiple aperture lists are generated for each layer or when the aperture list is generated in a format different from the Gerber files, the possibility for errors increase. Having a single detailed aperture list containing specifications for all the layers and in the same format as the Gerber files reduces the chances of errors and malfunctioning.

Zero byte Gerber PCB files

Sometimes design errors can lead to the creation of zero byte Gerber files that contain no information that can be used for PCB manufacturing and fabrication. It is important to check the validity of the Gerber file before sending it across to PCB manufacturers.

Incomplete or misleading Gerber file labelling

Each Gerber file needs to follow a standard naming convention that makes it easy for the manufacturer to understand its intended use. An incomplete or non-standard file labeling can create interpretation issues for the manufacturer leading to production errors and delays.

Insufficient inner clearance

Inner clearance can be defined as the minimum clearance required between the drill hole and the interconnected, adjacent inner layer copper on the printed circuit board. If the inner clearance is not sufficient, it can cause short circuit in the inner copper layer during the drilling process.

Errors in Making Composite layers

Some design software’s use compositing of layers while creating design specifications for individual layers. This can include layers with both positive and negative images and while compositing can help speed up the process it can also cause errors especially if the images are not combined properly to create a single Gerber file for each layer.

Gerber file errors can prove to be a costly and time consuming, not to mention completely avoidable. Ensure your PCB Making, manufacturing and fabrication process remains error free depends a lot on ensuring Gerber files are accurate and complete, which is possible by practicing the following steps

  • When it comes to ensuring error free operations, there is nothing like establishing best practices at every step of the design and manufacturing process. This includes checking the Gerber files for completeness, correctness and length as well as validity.
  • Use a Gerber file viewer to check the Gerber files for accuracy and validity. A Gerber file viewer allows designers to validate the size of the final actual PCB and even print a sample board to check for size.
  • Use advanced CAD software during the design process that are less prone to errors, some high definition CAD software are even able to provide designers with a basic design analysis before creating the actual Gerber files to be sent to PCB manufacturers and fabricators.

Adhering to these practices along with rigorous quality checks at every stage of the design process can ensure that the PCB’s manufactured by you are both high performing as well as long lasting.

Technotronix is one of the leading provider of PCB manufacturing services to all the dominant industries. Having a strong manufacturing unit with a strong tool room and a team of experts, we are the one that provides cost effective solutions with keeping quality at the nucleus in each stage of PCB manufacturing. To get proper consultation or share your requirements to get a perfect PCB with cost effective strategy or to get a quote, drop an email to [email protected] or give a call 714/630-9200!

PCB Fabrication Is Molding An Upward Curve Of Innovations In Building Protection System

By | Date posted: | Last updated: September 7, 2024
PCB Fabrication

Be it a residential building, hospital, shopping mall, hotel, school, educational institution or any kind of a building, the security of the building is a prime facet to get a complete building solution. This also includes protecting the building, its assent and the human life from the airborne toxic industrial chemical, radiological and biological attacks or any accidental release apart from fire, water, earthquake and other security concerns. For these high value security solutions, the upgraded technology for the building safety system is now a top priority, especially in the commercial building sector and residential constructions. To introduce a completely new concept and a unique solution, it is necessary to focus on the dynamic electronic design and manufacturing solution in consultation with the custom PCB experts.

The printed circuit boards used in the making of the building security devices have many PCB manufacturing techniques with which one can create an altogether a unique modification in the new and existing electronic equipment. The modification and discovery in the building protection system have an increased use of state-of-the-art PCB fabrication Innovation like Through-Hole-Technique, Surface Mount Technique, Cable Harness, Wire Harness and Box Build PCB assembly. To know about the ups and downs of the building security systems, it is also important to stay updated with the new innovation of the current times in the global market. Some of them are listed as under which has the highest requirement of varied pcb layout and fabrication services.

PCB Fabrication Innovations in Building Protection System:

Robust Fire detection System:

The flexible PCB is the foremost element in manufacturing the automatic fire detection technology and multi sensor devices for fire detection. This has also made it possible to get a hybrid instrument for fire detection that can also apply the modern signal processing techniques like fuzzy logic and neural network. This has made possible to bring new modifications in the fire risk assessment and fire fighting equipment for the building protection.

Electric Locking Mechanics:

The electronic devices having multiple functionalities like keyless electronic system, large scale entry solutions, retrofitting interior enclosure system, electromechanical lock and many more devices are used to provide security needs of electric locking mechanics.

Lightning Protection System:

The Lightning Protection System (LPS) provides safety of building from the destruction by the power of lightning that is directed towards the ground. For this, the rigid/flex PCB and cable harness PCB assembly are widely used in the electrical elements used in this lightning protection system with simple rods, triggering system and with taut wire. Among all, the lightning surge arrestor is in the mainstream that is used to protect the building from the havoc of lightning that can wreak on the delicate electronic instruments installed inside the building. These arrestor are installed on the electrical service panel that has a proper coat onto it that is capable enough to resist the direct lightning strike. This type of building protection system is majorly used in the metal covered buildings.

Fire Alarm System:

With rigid/flex printed circuit board and PCB prototypes, the fire alarm specialists are now able to bring new creative inputs into the device functionalities. Depending on the size of the building, the type of fire alarm system is decided as it has complex installations in the building. These consist of the hardwired system, conventional system, radio linked system and analogue addressable fire alarms.

Electric Smoke Detector:

A PCB used in smoke detection alarms need complex engineering and rigorous testing process to get a long estimated life of the batteries used in smoke detection devices installed in the building. Be it a hardwired AC operated or battery operated smoke detector, ionization and photoelectric technology has brought further improvements in the product performance and durability.

Induction loop and hearing enhancement system:
The wired or wireless induction loop system and hearing enhancement system with a high tech loop driver and audio source helps to catch the clear sound without interference.

Another new innovation is marked in the electric gauge door opener, cathodic building and structure protection, smoke alarms, burglar alarm, door monitoring and locking and fire door control devices. Above all the buzz word in building security market is the Eco-Friendly safety and security solutions to protect the building with the safety of the environment and human life as well.

TechnoTronix proffers a custom PCB prototype and PCB manufacturing solution with the help of well defined PCB fabrication process and fully equipped tool room. With a passionate team of technical experts, we provide complete turnkey solutions with quick turnaround and timely delivery of order to our customers. Having good PCB assignments of building protection devices and equipment, our research team has made us one of the renowned players in providing electronic and layout solution to the building security and safety requirements.

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