A Closer Look at IPC X-Ray Inspection Guidelines for BGAs

Date
- (12:00 - 1:00pm CDT)

Ball Grid Array (BGA) defects pose significant challenges in circuit board assembly. The IPC guidelines provide a foundational framework for inspection, yet they may not encompass all scenarios effectively. Leveraging the latest advancements in 3D Computed Tomography (CT) technology allows for a detailed examination of each solder ball, facilitating a precise identification of common defects such as voiding, non-wetting, and head-in-pillow phenomena. Through this approach, engineers can conduct a thorough root cause analysis, enhancing the reliability of electronic assemblies.

Speaker Bios

Nick Fieldhouse September 18

Nick Fieldhouse is a Product Manager specializing in Omron’s Automated Optical and X-Ray Inspection solutions. During his nine years at Omron, Nick has gained experience as an Application Engineer and Engineering Supervisor. Additionally, he has presented at major conferences, sharing his expertise on subjects such as “The Benefits of CT X-Ray Inspection” and “Smart Factory Manufacturing.” Nick holds both a Bachelor’s and a Master’s degree in Mechanical and Materials Engineering, which he earned from Pennsylvania State University.

 

 

 

 

 

The Engineering Webinar Series will provides FREE, live, monthly educational experiences and videos discussing key design issues surrounding aspects of quality, defect detection & remediation, and design finalization & fabrication. All sessions are recorded and registered attendees will receive a link to the video to watch on-demand. 

Electronics Industry Sentiment Rebounds in August After Three-Month Decline

IPC releases August 2024 Global Sentiment of the Electronics Supply Chain Report

Sentiment in the electronics industry saw a modest uptick in August, though it remains below the peak observed in April 2024. The improvement was driven by stronger demand and reduced costs according to IPC’s August Sentiment of the Global Electronics Manufacturing Supply Chain Report.

Regarding current supply chain conditions, half (50 percent) of electronics manufacturers are currently experiencing rising labor costs, with 46 percent reporting increased material costs. At the same time, ease of recruitment, profit margins, and backlogs are presently declining. Over the next six months, electronics manufacturers expect labor and material costs to remain high, although relatively stable. Profit margins and backlogs are expected to rise, with recruitment challenges continuing to persist.

In response to special questions on geopolitical risks and trade policies and tariffs affecting business operations, more than two-fifths (42 percent) of respondents are very or extremely concerned about geopolitical risks and 44 percent are concerned with trade policies and tariffs, with no significant differences by geographical regions.

Additional survey data show:

  • The Demand Index increased 3.3 percent in August.
    • This rise was fueled by better, albeit still contracting, backlog, capacity utilization that shifted to expansion, and heightened order sentiment.
  • Cost pressures eased slightly in August, with both the Labor Costs Index and the Material Costs Index dropping by one point.
    • Despite this decline, both indexes remain in expansionary territory, indicating that a majority of businesses continue to face cost challenges. Notably, the Labor Costs Index hit a new low for the year.
  • Industry outlook Improves in August.
    • The overall industry outlook remained robust in August, although demand sentiment has cooled from earlier highs this year.

These results are based upon the findings of IPC’s Current State of Electronics Manufacturing Survey, fielded between July 18 and July 30, 2024.

Read the full report.

Latest Advancements in High-Reliability Electronics Focus of 2024 IPC High Reliability Forum

Forum co-located with IPC Builds, IPC standards development committee meetings

Ensuring reliability in high-voltage electronics, a new standardized test method for abrasion resistance of e-textiles, and assembly and solder joint X-ray challenges are just a few of technical conference topics offered at IPC’s High Reliability Forum October 9-10 at the McKimmon Center in Raleigh, N.C.

Additional presentation topics cover: safety critical electronics considerations; military, aerospace, medical, automotive, e-Mobility and other applications with specialized reliability requirements; and industry-curated content covering many different topics related to high reliability issues in PCB design, PCB fabrication materials, PCB assembly, PCBA surface reliability, emerging electronic technologies, mitigation strategies and test methods.

Speakers from the following companies include Denis Barbini, Ph.D., Zestron; Steven Dirkes, U.S. Army; Ben Gumpert, Lockheed Martin; Norbert Holle, Ph.D., Robert Bosch GmbH; Takenori Kakutani, Taiyo Ink Manufacturing; Tony Lentz, FCT Assembly; Bob Neves, Microtek Laboratories & Reliability Assessment Solutions; Tim Pearson, Collins Aerospace; Erin Tillery, NC State University; and Udo Welzel, Ph.D., Robert Bosch GmbH. View complete speaker lineup.

“The event provides a unique opportunity for those in industry who design, manufacture, or test electronics for critical applications with unique safety, reliability, and lifetime requirements to obtain the latest research on high-reliability electronics,” said Teresa Rowe, IPC senior director, assembly and standards technology. “This year, attendees will learn about the newest research and emerging trends in high-reliability electronics, hear from subject matter experts, connect with exhibitors and peers, and take advantage of several networking opportunities during the course of the two-day forum.”

IPC High Reliability Forum will be co-located with IPC Builds which is being held October 5-10, 2024, at the McKimmon Center. IPC Builds focuses on IPC standards development committee meetings and encourages industry’s contribution to the standards and guidelines that companies and their customers, suppliers, and competitors rely on. Separate registration is required.

For more information on the IPC High Reliability Forum including agenda, speaker profiles, exhibition and sponsorship information, or to register for event, visit www.ipc.org/event/high-reliability-forum. For more information on IPC Builds, visit www.ipc.org/event/ipc-builds-standards-development-committee-meetings.

Demystifying the EU Corporate Sustainability Due Diligence Directive (CSDDD) for the Electronics Manufacturing Industry

Date
-

The Corporate Sustainability Due Diligence Directive (CSDDD) is a European Union directive that introduces legal obligations on businesses to respect human rights and the environment. It requires applicable companies to conduct human rights and environmental due diligence across their global value chain. It also includes certain obligations regarding climate change as well as language empowering victims of corporate abuse to sue companies before national courts of EU Member States for harm occurring within their value chain.

By attending this webinar, you will:

  • Learn about the scope, applicability, and objectives of the Corporate Sustainability Due Diligence Directive 
  • Understand what is needed to ensure that your value chain actors respect human rights, adhere to environmental standards, and implement good governance, and
  • Discover practical steps to get started conducting due diligence to mitigate risks across your value chain and demonstrating compliance with the Directive.
Online Event

3000 Lakeside Dr.
Suite 105N
Bannockburn, IL 60015
United States

Online Event

Online Event
3000 Lakeside Dr.
Bannockburn, IL 60015
United States

Private Wireless Networks for Digital Transformation of Manufacturing

Member Download (pdf)

To drive digital transformation and leverage the power of data through analytics, machine learning, and artificial intelligence, enterprises need secure networks that provide mobility, real time visibility to operational data, and the ability to instantly communicate with “man or machine” via voice, video, and data. Unfortunately, broadband connectivity at most enterprises today is a hodge-podge of wireless cellular connectivity, wired internet access, enterprise owned WiFi networks, and walkie-talkie style two-way radio communications. As a result, enterprises face uncontrolled costs, indeterminate security risks, and unmanageable operational complexity.

With the release by the Federal Communications Commission of 150 MHz of Citizen’s Broadband Radio Spectrum (CBRS Band 48, 3.55 – 3.70 GHz) on unlicensed/lightly licensed basis, enterprises large and small can now afford secure, lightning-fast, private broadband wireless networks that deliver the control, predictability, and security of wired connectivity with the mobility, scalability, and ease of implementation of wireless.

Using a case study from enterprise operations, this paper discusses the pros and cons of cellular versus WiFi technologies, cost-benefit analyses of the technologies, and the benefits of private enterprise owned versus carrier owned networks for digital transformation of enterprise operations to Industry 4.0 standards.

Author(s)
Aroon Tungare, Tom Zurawski, Marc Metteauer, Steve Wilson
Resource Type
Technical Paper
Event
IPC APEX EXPO 2023

Raising the Level of Supply Chain Trust for the Future Factory

Member Download (pdf)

Recently, there has been an increase in production stoppages due to cyber-attacks on suppliers. Criminals attack the weakest point of your supply chain. However, little progress has been made in increasing the level of trust in the supply chain, as an essential countermeasure, especially in SMEs suppliers . In this paper, we explore how-to step-up supply chain trust in two ways.

The first method is to raise the cybersecurity awareness level of small and medium-sized suppliers that supply parts and materials. Supporting security personnel and addressing general weaknesses in the IT system itself is usually provided by large companies and security firms. The definition, however, of critical information that must be protected, and the analysis of current threats, are not well advanced, as this knowledge is internal to SMEs. Imagine this. If you walled off your village, what treasures would you protect, where would you put them? Who would control the locks, how would you post guards, etc., or they would be stolen by bandits in no time? In other words, they are not progressing due to bottlenecks in areas that cannot be recognized by large external companies. Our experience will show you how to move your internal personnel forward to find the core knowledge that affects the functional quality of your products, the critical first step, and then to identify threats from a criminal's perspective.

The second method is the advancement of logistics and maintenance, which involves more people. From our experience, we will show how we understand the difference between a factory and a logistics and maintenance supplier in terms of trust, and how we have advanced our logistics and maintenance suppliers.

We believe that increasing supply chain reliability in the above two areas will increase mutual trust and promote supply chain trust, essential, for example, for smart city security.

Author(s)
Hiroyuki Watanabe
Resource Type
Technical Paper
Event
IPC APEX EXPO 2023

A New Approach to Conformal Coating Demonstrates Significantly Improved Ruggedization Performance

Member Download (pdf)

IPC-TR-587 technical report, ‘Conformal Coating Material and Application ‘‘State of the Industry’’ Assessment’ [1] outlines an IPC study of major conformal coating types, coating application techniques, and coating cure technologies, characterizing the final film thickness on common component surfaces. In many cases, the film thickness, although visually not zero, was below the limit of measurement. In ‘Conformal Coatings: State of the Industry Vs of state of the Art’ [2] it was clearly demonstrated that conformal coating coverage and thickness are clear performance indicators of the propensity for a coating material to provide protection in harsh environments, e.g. condensing, salt-spray, immersion and mixed flowing gas etc.

Whilst state of the art materials improved protective performance by at least two orders of magnitude compared to the legacy materials, the paper highlighted areas for improvement, especially with regards to component tolerances. A natural, slight shift in position of components during soldering could yield very different coating patterns and coating coverage, resulting in inconsistent protection from one board to the next.

In this paper, we show how the creative use of liquid coating chemistry can permanently solve coverage issues within the current application paradigm, leading to improved ruggedization performance outcomes in immersion and condensing environments. The results clearly show consistently improved results for the new approaches providing significant enhancement of ruggedization performance.

Author(s)
Phil Kinner, Beth Turner, Chris Allen
Resource Type
Technical Paper
Event
IPC APEX EXPO 2023

An Efficient and Innovative Cleaning Solution with Low Environmental Impact

Member Download (pdf)

Contamination of electronic assemblies can occur at any process steps and can be of different natures such as oxides, organic residues, or dusts. Those contaminations could reduce the reliability of PCBA through time. At the same time, miniaturization and new component typologies require ever-higher performances with ever-increasing functionality. Moreover, the industry is looking for solutions to improve cleaning efficiency, reduce costs and limit environmental impact. Thus, developing cleaning solutions become a challenge to guarantee the reliability of the electronics assemblies.

This paper introduces a new technology of cleaning solution developed to be compatible in several processes. After a short description of co-solvent and aqueous process, the cleaning results concerning the new technology that can work in both processes are shared. The cleaning efficiency is evaluated using IPC standards: visual inspection under microscope, ionic contamination, and SIR test. Surface tension is also measured.

Then, a scoring method based on the GHS labelling system and REACH regulation is used to evaluate the environmental impact of this innovative cleaning solution technology.

As a conclusion, the new cleaning solution does show promising results. For aqueous processes, this improvement allows to lower the cleaning time and/or the cleaning temperature. For co-solvent processes, the cleaning performance is similar with an improvement of the safety and the environmental footprint.

Author(s)
Laura LeComte, Christophe Dehon
Resource Type
Technical Paper
Event
IPC APEX EXPO 2023

New Resin Systems used to Solve Circuit Board Fabrication Issues

Member Download (pdf)

As new materials have been developed over the last few years, including the increasing use of thinner dielectrics and spread glass to help improve electrical performance, new issues have been introduced into the fabrication process.

Some of the issues with these new materials include increasing thickness variation due to low pressure areas and uneven copper distribution through the stack, and voiding due to lower resin flow. More complex designs can include thin drilled and plated subassemblies requiring hole fill, which can be a challenge for the fabricator due to scaling or stretching of the materials during the planarization process. This issue becomes even more exaggerated with softer RF materials.

This study looks at solutions to these problems and includes via filling without the planarization step. We also look at methods to produce very flat surfaces to enable more accurate back drilling and produce a flatness tolerance acceptable for large ball grid array packages during the assembly process. Spread weave glass materials have limitations due to low resin flow through the glass and can cause voiding. This limits the designer and can force the addition of more layers using lower copper weights for power planes. Micro cracking is caused by resin rich and resin poor areas having mismatched CTE values. The heavy weight of the copper is a challenge to produce without some level of voiding. This study looked at a 20-layer 4oz copper planar magnetic design in which a high flowing non-reinforced material is employed to overcome these challenges.

Author(s)
Steve Schow, Bob Gosliak, Thomas McCarthy
Resource Type
Technical Paper
Event
IPC APEX EXPO 2023