Microboard, a leading Electronics Manufacturing Services (EMS) provider, faced mounting challenges in its printed circuit board (PCB) assembly process related to underfill applications. The previously dependable Asymtek S-920N underfill machine, in service for over a decade, was nearing obsolescence due to waning spare parts support. This, coupled with escalating customer demands, necessitated a technological upgrade.
The underfill process itself presented inherent complexities. While crucial for preventing solder fractures under Ball Grid Arrays (BGAs) in demanding environments, underfill is not universally required for all PCBs. Moreover, the irreversible nature of the process demanded precision and selectivity. These factors converged to necessitate a more advanced and adaptable underfill solution capable of addressing Microboard’s evolving production needs.
investigation
To rectify these challenges, Microboard implemented the PVA Delta 6 selective coating/dispensing system. This high-precision, robotic platform is engineered for underfill and conformal coating applications. Core to the Delta 6’s capabilities are:
- Enhanced Precision: Equipped with closed-loop servo motors and high-resolution encoders, the Delta 6 delivers unparalleled accuracy and repeatability in underfill dispensing, significantly reducing defects.
- Increased Flexibility: The machine’s versatile gantry system and advanced software accommodate a wide range of PCB sizes and complexities, optimizing production efficiency.
- Improved Efficiency: Faster cycle times, averaging 1:30-3 minutes per board compared to the previous machine, and streamlined setup procedures contribute to heightened throughput and overall operational efficacy.
The Delta 6 was selected due to its superior performance metrics, adaptability, and alignment with Microboard’s growth trajectory. Its “Made in America” designation and proximity of the manufacturer in New York also factored into the decision, ensuring reliable support and maintenance.
solution
The integration of the PVA Delta 6 has yielded transformative results for Microboard. The machine’s precision has been instrumental in achieving a 40% reduction in underfill-related defects, such as overfill and underfill, within the first six months of operation. This improvement is directly attributable to the Delta 6’s advanced dispensing technology and robust process control.
Furthermore, the Delta 6’s flexibility has expanded Microboard’s underfill capabilities to a broader spectrum of PCBs. The machine’s adeptness in handling diverse board configurations; including complex assemblies featuring AMD Virtex-7 XT chips with over 500 connections, in addition to various BGA part numbers with high connectivity, has contributed to a 18% increase in production efficiency.
Concurrently, the Delta 6’s accelerated cycle times and simplified setup procedures have collectively augmented throughput by 15%. This enhanced productivity has been pivotal in meeting burgeoning customer demands, including expedited prototype builds for a long-time customer and compressing delivery timelines.
conclusion
The incorporationof the PVA Delta 6 underfill machine has proven to be a strategic catalyst for Microboard’s PCB assembly operations. By effectively addressing the limitations of its predecessor and capitalizing on the Delta 6’s advanced capabilities,
Microboard has achieved substantial advancements in underfill quality,
efficiency, and flexibility.
The resultant decrease in defects, amplified production capacity, and optimized process control have solidified Microboard’s position as a preeminent electronics
manufacturer. This underscores the transformative potential of cutting-edge
automation technology in driving operational excellence and delivering superior
customer value.
