Calumet’s investment in two AccuSystems scoring machines demonstrates its commitment to precise dimensions of finished customer parts. The AccuSystems scoring machines provide the following benefits to Calumet’s customers: •
Precise and repeatable accuracy is achieved through twin Z axis drive systems mounted to a rigid steel frame.
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Quick and intuitive job setup is accomplished with a graphical Windows-based programming environment.
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A shared job database ensures that each customer’s CAM requirements are accurately relayed to the machine operator and that the requirements remain consistent across each scoring machine.
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Continuous and segmented ‘jump’ v-grooves can be scored on one or both sides of a PCB panel at speeds up to 200 feet per minute (FPM) offering complete flexibility in meeting customer requirements.
There is a difference in process capability.
A difference in capability.
AccuSystems Scoring Machines
Five EMMA Flying Probe Testers are in use at Calumet for electrical testing of completed PCBs. All five EMMA testers obtain identical Genesis CAM data from a shared network location ensuring that all parts are electrically tested to original customer data. EMMA flying probe technology ensures high speed accurate tests without incurring the costs of expensive fixtures. EMMA testers perform continuity and isolation tests simultaneously on both sides of the PCB. EMMAs innovative clamping system removes any warpage which may impact targeting accuracy. There is a difference in test technology.
A difference in capability.
Microcraft EMMA Electrical Tester
Calumet has invested in the innovative technology and advanced engineering of Hitachi drill machines. Hitachi produces the fastest, most accurate, and most reliable CNC PCB drilling machines on the market. Hitachi drill machines provide the following benefits to Calumet and its customers: •
Reduced bit exchange time using Hitachi’s quick insert changer
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Chip clogging prevention using cyclone jet technology
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Reliable broken bit detection accomplished with a unique method of counting chips and maintaining long term stability.
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Stable small hole drilling with minimal bit breakage using a front thrust spindle
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Flexible tool management with the easy-handling tool cassette design
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Panel scrap eliminated through the use of the tool height detector that prevents the use of damaged or wrong size tools
There is a difference in drilling technology.
A difference in capability.
Hitachi Drill Machines
Calumet uses seven OLEC AccuTray™ AT 30 Auto Align Imaging Machines. Four AccuTrays are used for imaging copper layers. Three AccuTrays are used for imaging soldermask and silkscreen layers. The AT 30s provide Calumet with the following advantages: •
Automatic alignment of Phototools with precise registration
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Quick and easy artwork set-up and change-over
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Go and no-go print settings
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Film-to-film, panel-to-film, and fiducial-to-film registration options
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Dual-tray configuration for increased productivity
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Four cameras per tray for precise registration
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Pre and post-vacuum registration verification
There is a difference in imaging.
A difference in capability.
Olec AccuTray AT 30
Measurement of registration and internal features at Calumet is automated with the use of an Optek InnerVision X-ray inspection and measurement system. The benefits achieved with the InnerVision include: •
The ability to quantify offset, skew, stretch, shrink, and other internal details of multi-layer printed circuit boards.
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Accurate stage positioning with no-maintenance precision linear motors.
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High resolution intensified x-ray camera providing a brilliant video image for visual verification.
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The ability to measure a variety of layer counts and thicknesses with programmable x-ray voltage and illumination settings.
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Superior machine stability accomplished with the InnerVision’s massive granite base.
There is a difference in inspection.
A difference in capability.
Optek InnerVision
Dimensional inspection at Calumet is automated with the use of an Optek VideoMic measurement system. The benefits achieved with the VideoMic include: •
Enhanced video edge detection allowing for verification of critical dimensions using a variety of reference features.
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Smooth and accurate transport with lead screw driven micro-stepper motors.
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Measurements referenced to both precision glass scales and pixel calibration in the camera image.
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High resolution color camera providing a brilliant video image for visual verification.
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Increased accuracy and stability using precision linear ways and air bearings.
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Superior machine stability accomplished with the VideoMic’s massive granite base.
There is a difference in inspection.
A difference in capability.
Optek VideoMic
At Calumet, three Orbotech Discovery 8 AOI machines are used for inner and outer layer inspection. The Discovery 8 is designed with SIP Technology™ allowing faster comparisons between data provided by CAM and data acquired from the production panel. Enhanced imaging is accomplished by distributing the computing workload across multiple processors. Built-in Visual Intelligence ™ eliminates time-consuming false calls. This breakthrough technology automatically distinguishes between critical and noncritical defects allowing operators to concentrate on true defects. Additional time-savings and comparison accuracy are accomplished through a direct interface between the Discovery 8 software system and the Genesis CAM software. This interface ensures that every production part is precisely compared against the original customer design. There is a difference in inspection.
A difference in capability.
Orbotech Discovery 8 AOI Machines
Calumet has invested in two Orbotech LP9008 automated high-resolution laser plotters. Calumet’s imaging process benefits from the following LP9008 features: •
120-beam laser
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Resolutions as fine as 25,400 dpi
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Superior geometric and feature accuracy
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Full, advanced automation
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Continuous plotting of up to 300 films
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Integrated advanced plot queue
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Full integration with Calumet’s Genesis CAM software
There is a difference in imaging.
A difference in capability.
Orbotech LP9008
Calumet has invested in two automated vertical plating lines from Process Automation Limited, LLC. Each plating machine is equipped with eighteen stages including six copper plating stages and one tin plating stage. Transporter control is managed by a PLC housed in a separate control cabinet. Mechanical agitation is provided on all process and rinse tanks. Plating process variables are managed through OSST software ensuring consistency and eliminating human error. There is a difference in process capability.
A difference in capability.
Automated Electroplating Equipment
Calumet uses a Pluritec INSPECTA L to x-ray and then drill “best fit� tooling holes unique to each production panel. The unique tooling holes result in precise production drilling and an increase in multilayer registration accuracy. The INSPECTA L is a single spindle x-ray drilling machine with linear motors. The machine is equipped with one drill spindle, one CCD camera, and one micro-focus x-ray source. Combined with Gemini-X registration control software from XACT PCB, x-ray results from the INSPECTA L provide stunning breakthroughs in the registration process. There is a difference in registration accuracy.
A difference in capability.
Pluritec X-ray Drilling Machines
Calumet has made a major investment in equipment designed to clean and prepare drilled holes and board surfaces prior to electroless processing. The Cemco-Fsl Hole Blaster removes drill debris using twin high velocity air jets oscillating across the upper and lower surfaces of the panel. The output conveyer then feeds the panel to the Pola & Massa modular scrubbing and deburring machine. The Pola & Massa further prepares the panel as follows: •
An air knife removes additional debris from drilled holes.
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The board is then scrubbed with four auto-adjusted scrub brushes.
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Following scrubbing, the board goes through a rinse, a high-pressure rinse, and is dried.
The process is fully automated and managed through an Omron PLC ensuring consistent preparation and cleaning for every panel. There is a difference in process capability.
A difference in capability.
Post-drilling Surface and Hole Preparation
At Calumet, two Schmid DevelopEtch-Strip lines are used for inner layer core processing. Equipment from the Schmid Group is known for its modular design and ease of maintenance. Innerlayer cores are run through a three-step conveyerized process: •
At the develop step, unexposed resist is developed out.
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At the etching step, bare copper is sprayed with an acid etching solution and removed down to the base material.
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At the stripping step, resist is stripped by an alkaline solution and filtered out.
Schmid Develop-Etch-Strip equipment allows Calumet to process thinner multilayer core material contributing to a higher density and higher quality finished product. There is a difference in process capability.
A difference in capability.
Schmid Develop-Etch-Strip Machine
At Calumet, a Schmid Strip-Etch-Strip line is used for outer layer processing. Equipment from the Schmid Group is known for its modular design and ease of maintenance. Outer layer product is run through a three-step conveyerized process: •
At the stripping step, the photo resist is removed in an alkaline etching solution.
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At the etching step, copper not protected by metal resist is etched off using an ammoniacal solution.
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At the tin stripping step, the metal resist layer (tin or tin/lead) on the features is removed.
Schmid Strip-Etch-Strip equipment allows Calumet to precisely control intermittent spray modules for ultrafine lines resulting in a higher technology and higher quality finished product. There is a difference in process capability.
A difference in capability.
Schmid Strip-EtchStrip Machines