QUALITY CONTROL STEPS DURING PROCESS_Shenzhen Pcbion Electronics Co., Ltd

QUALITY CONTROL STEPS DURING PROCESS

Safe-PCB performs many quality checks during the manufacturing process.

Defective PCBs are discarded or repaired (except IPC-A-600 class 3) for compliance.

Here is the table summarizing the quality checks carried out during the process.

	Control	Equipment	PCB type / option	class 2	class 3
1.0 - Customer technical files (gerber)	Digital image	Safe gerber viewer	All PCBs	Yes	Yes
2.0 - Safe-PCB manufacturing files	Netlist compare	CAM350 function	All PCBs	Yes	Yes
3.0 - Laminate cut	Copper/insulator thickness control	Copper thickness meter / magnetic induction	All PCBs	Yes	Yes
4.0 - Drilling	Tool diameter control	Laser measurment on machine	All PCBs	Yes	Yes
4.1 - Drilling	Hole diameter after drilling	Tunnel hole checker	All PCBs	Yes	Yes
5.0 - Etching	Internal layers etching quality	AOI	All multilayers	Repair accepted	No repair accepted
5.1 - Etching	External layers etching quality	AOI	All PCB	Repair accepted	No repair accepted
6.0 - Press	Dimensional measurement	ASIDA - optical control	Multilayers / blind holes	Yes	Yes
6.1 - Press	Layers alignement	ASIDA -X-RAY control	Multilayers / blind holes	Yes	Yes
7.0 - Metallization	Copper thickness measurement	Thickness measurement probe	All PCBs	Yes	Yes
8.0 - Soldermask	Soldermask quality	Visual inspection	All PCBs	Yes	Yes
9.0 - Electrical test	Open/short circuits	Flying probe test or pin mould	All PCBs	Yes	Yes
9.1 - Electrical test	Resistance control	Resistive probe test	Multilayers / blind holes	Yes	Yes
10.0 - V-CUT	Depth V-CUT control	Depth gauge	All PCBs	Yes	Yes
11.0 - Milling	Dimension control	Calipers	All PCBs	+/- 150 µm	+/- 150 µm

1.0 - GERBER VALIDATION BY DIGITAL IMAGE

PCB checked using this procedure : 100% of PCB.

Safe-PCB asks the customer to validate their PCB design after it's checked by our technicians.

Safe-PCB provides a digital image of the final PCB result to the customer at this step of the process.

An order can NOT be produced without previous customer GERBER validation.

2.0 - CAD - NETLIST COMPARISON - 100% OF PCB

PCB checked using this procedure : 100% of PCB.

Before production of the PCB in our factory, every order's manufacturing file is checked by our technicians to make sure it's totally conform to the original GERBER file provided.

This is done by a software function called Netlist compare, which compares the original GERBER file and manufacturing file.

4.0 - OPTICAL INSPECTION OF HOLES DIAMETER

PCB checked using this procedure : 100% of PCB.

After drilling, Safe-PCB optically checks the holes diameter.

This test is done using a semi-automatic equipment (Picture on the right) that compares it to the drillmap provided with the GERBER file.

Each drilled hole is controled with this equipment.

5.0 - AOI - AUTOMATIC OPTICAL INSPECTION TEST

PCB checked using this procedure : all multilayer PCB.

The AOI test is used to check multi-layer boards.

It allows to optically monitor possible etching flaws, using a light source (laser or LED) and an image capture system (scanner or camera).

The test is performed before pressing the layers by comparison with the gerber file.

The test can detect manufacturing flaws that may go unnoticed at the electrical test.

6.0 - LAYERS ALIGNMENT CONTROL

PCB checked using this procedure : 100% of multilayer PCB containing blind holes.

PCB with blind holes need a perfect layer alignment. Safe-PCB checks these PCB using two complementary equipments:

. One optical ASIDA equipment that controls the PCB before the pressing step

. One X-Ray ASIDA equipment that controls the PCB after the pressing step

The optical equipment (Picture on the right) allows Safe-PCB to control the internal layers dimensions before pressing, preventing bad alignment of holes and copper tracks

In addition to the ASIDA machine, Safe-PCB checks these PCB using a X-ray machine.

This equipment irradiates the PCB with X-rays allowing Safe-PCB technicians to control the alignment of inner layers after the pressing step with a camera. This system is similar to a medical X-Ray radiography.

MICROSECTION

PCB this procedure applies to : 100% of multilayer PCB.

This step of the process takes place after applying the surface finish on the PCB. A technician cuts a small piece of panel and checks :

. Copper layers thickness

. Hole copper thickness (PTH)

. PP (Prepreg) layers thickness

He then reports these measures on the picture of the microsection.

During the final quality control step the picture of the microsection is uploaded to the quality control report.

Microsections of 4...8 layers PCB below.

9.0 - ELECTRICAL TEST

By default, Safe-PCB routinely passes all electrical circuits to test before packing and delivery.

The electrical test covers all types of short-circuits and all the breaked tracks or vias.

Prototypes and small series undergo E-test performed using flying probe testers. Safe-PCB currently uses 9 flying probe testers :

- 5 ADLONG KS1000 testers

- 3 KEHUILONG XC 600 testers

- 1 SPACELIGHT ESL618-L tester

Larger series are tested using a testing framework needle - requires the manufacture of a dedicated file for each manufacturing equipment. Safe-PCB currently uses 2 of these :

- 1 KEHUILONG KHL910 tester

- 1 WTD HV300

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