Würth Elektronik (WE) installed two UV/IR exposure units from Limata at its Rot am See site in 2019. After two years of operating experience, Hannes Scheuerlein, Head of Photo Processes at WE, and Mirjam Vogl, Limata, spoke about the project.
"The LUVIR technology already impressed us during the test phase," says Hannes Scheuerlein The LUVIR technology is described as an "impressive combination of IR and UV laser": The IR laser is absorbed by the coating and thus excites it before the actual UV exposure in such a way that only a fraction of the usual UV exposure energy is sufficient to achieve the desired polymerization. This is also confirmed by the experience of the user WE.
The WE production site in Rot am See (currently 150 employees) produces up to 120 different PCB designs per day in 3-shift operation for samples and small series for leading customers from the automotive supplier sector, industrial electronics and medical technology. Before the Direct Imaging systems were installed, the long exposure times of conventional coatings and manual multi-shift operation (manual imagesetters) had increasingly led to production bottlenecks and therefore higher process costs. In 2019, WE therefore decided to install the X1000 system solution with two UV/IR exposure units as the X1200_SM.
Two years after commissioning this system solution, Mirjam Vogl asked WE in Rot am See about their experiences with the new machine, the LUVIR technology and the service. Hannes Scheuerlein, Head of Photo Processes at WE, answered these questions:
Vogl: What experiences have you had since purchasing the machine?
Scheuerlein: Efficient direct imaging has made the output more effective. As a result, we have not only been able to increase the internal service level, but also greatly improve delivery reliability.
Vogl: Initially, the LUVIR technology was still completely new to you ...
System solution X1200_SM at Würth Elektronik in Rot am SeeScheuerlein: Yes, initially we were sceptical about the technology, as we could not imagine that by 'simply' heating the coating before the actual UV exposure, only a fraction of the usual laser power would be required to achieve complete polymerization. However, the test phase was able to dispel our doubts. After a short evaluation phase, we took the system into production and it has been an important part of our machinery for more than two years now.
Vogl: Were you able to overcome the production bottlenecks you were experiencing at the time in manual multi-shift operation with a manual imagesetter?
Scheuerlein: Yes, thanks to the purchase we can produce around 300 more panels per day. This has enabled us to overcome the bottlenecks and increase production capacity at the same time.
Vogl: Has the use of the machine also saved you process time and costs?
Scheuerlein: Definitely. The throughput compared to our other direct exposure machine for the solder mask was increased by a factor of 10. There is also a positive side effect of this time saving for us as employees: with the X1200_SM, we are able to carry out the necessary work during regular working hours for any larger projects, so that no extra shifts are required. In addition, fewer films and less process chemicals are required for film production.
Vogl: What do you say about the quality of the exposed panels/conductor plates?
Scheuerlein: The LUVIR technology already impressed us during the test phase. Initial errors were rectified immediately and so we were able to make the purchase with a clear conscience.
Vogl: How would you rate the 'ease-to-use'?
Scheuerlein: The X1200_SM is very user-friendly. After a short familiarization phase, all employees were able to operate the system independently. Even temporary staff from other production areas or vacation workers who are new to operating the direct imager can familiarize themselves with the operation in a short time thanks to the 'simple' user interface.
Vogl: How do you rate the price-performance ratio of the machine?
Scheuerlein: The price-performance ratio is justified in view of the innovative LUVIR technology and the associated performance in the area of solder resist exposure.
Vogl: In your opinion, what is the main benefit of purchasing the X1200_SM?
Scheuerlein: In a nutshell: the improvement in yield and the associated service level for our customers.
Vogl: Did the experience meet your expectations?
Scheuerlein: Yes, absolutely. Looking back over the two years, the move to the new LUVIR technology in the field of conventional solder mask exposure has paid off in many respects.
Vogl: How did you find Limata's customer service over the last two years?
Scheuerlein: We have been very satisfied with customer service over the past two years. On-site visits were easy to implement due to the close proximity and, thanks to 'Remote Support', Limata's technical team was able to provide installation, maintenance and service support for the machine in real time via remote control, even during the pandemic. This meant that machine availability could be maintained at all times.
The X1000 series from Limata
The universal and cost-efficient LDI system platform has been developed for use in high-volume and small batch (high mix) environments in PCB production. The system can be used flexibly for the exposure process for high-resolution dry film, solder mask and marking printing.
The system platform ensures maximum efficiency and throughput by using Limata's proprietary LUVIR (UV/IR) technology for solder mask imaging. This technology is a combination of UV laser and IR laser power, where the IR laser is used for short-term heating, milliseconds before the UV laser starts polymerization. The heat makes the coating systems more reactive to the polymerization process, significantly reducing the UV power required for complete polymerization. This results in a faster and more efficient solder mask exposure process at higher capacity (prints per hour) without compromising on surface quality, resolution and accuracy.
Leading PCB manufacturers in Europe, USA and now also in Asia have been successfully using LUVIR technology for over 3 years.
The acquisition and follow-up costs of the X1000 ('Costs of Ownership') are significantly lower than the costs of alternative LED/DMD exposure systems due to the reduced number of UV laser components installed in the system. Without the IR laser, these require significantly more UV LED power (heads) to expose conventional coatings with high energy requirements. This is ideal for PCB manufacturers (or special PCB departments in the corporate environment) with high-mix/low-volume production mixes or exposure requirements of up to 750 panels/day in multi-shift operation (BASIC, HDI, Flex Solutions).
WE
The Würth Elektronik Group, headquartered in Niedernhall, Germany, is one of the leading suppliers of electronic & electromechanical components, control systems and printed circuit boards. The internationally active group of companies is one of the most successful companies in the Würth Group and consists of three independent divisions. Würth Elektronik employs around 7300 people worldwide and generated sales of EUR 823 million in 2020.
