Handbook of Printed Circuit Manufacturing, Softcover reprint of the original 1st ed. 1985

Of all the components that go into electronic equipment, the printed circuit probably requires more manufacturing operations-each of which must be per­ formed by a skilled person-than any other. As a shift supervisor early in my printed circuit career, I had to hire and train personnel for all job functions. The amount of responsibility delegated to my subordinates depended strictly on how well I had been able to train them. Training people can be a trying experience and is always a time-consuming one. It behooved me to help my workers obtain the highest degree of job under­ standing and skill that they and I were capable of. One hindrance to effective teaching is poor continuity of thought, for example, having to say to a trainee, "Wait a minute; forget what I just told you. We have to go back and do some­ thing else first. " It was in trying to avoid pitfalls such as this that I undertook a detailed examination of the processes involved, what I thought each trainee had to know, and what questions they would most frequently ask. From this analysis I developed the various process procedures. Only after I had done so was I able to train effectively and with the confidence that I was doing the best possible job. Answers had to be at hand for all of their questions and in what­ ever detail they needed to know.

Section 1. Design and Manufacture of Printed Circuits.- 1. How Printed Circuit Boards Are Manufactured: Processes and Materials.- What Is a Printed Circuit Board?.- What Is the Dielectric Substrate Made Of?.- The Manufacturing Process.- Bare Board Electrical Testing.- Dielectric Substrates.- 2. Computer Aided Design and Design Automation.- Using CAD.- Comparing Design Automation to CAD.- 3. Digital Printed Circuit Design.- Definitions.- Section 2. Planning, Document Control, and Quality.- 4. Definitions.- 5. Planning.- Planning Responsibilities.- Planning Procedures: Refer to Copy of Traveler.- Planning Order of Priority.- New Revisions.- Reorders.- 6. Quality Assurance Program.- Dealing with Customers and Product Returned by the Customer.- Underwriters Laboratories (UL).- Military Certification.- Summary.- 7. Quality Assurance Manual.- Elements of Quality Assurance 91 Calibration Program.- Inspection Stamp Control.- Inspection Supervisor Duties.- First Article Inspection.- Inspection Procedures.- First Inspection.- Final Inspection Procedure.- Processing Non-Conforming Product.- Processing Re-Works.- Military Specification Printed Circuits.- Processing of Returned Product.- Section 3. Imaging and Artwork.- 8. Artwork Processing.- Exposing.- Developing.- Definitions.- Customer Artwork Inspection.- Copy to Make Copies.- Step and Repeat (Using Diazo Containing Silver Film).- Soldermask.- Multilayer.- Repeats.- Spreads and Chokes.- Photo Supervisor.- 9. Artwork Registration Systems for Dry Film Imaging.- Pin Registration.- Visual Registration.- The Horning Pin Registration Method.- 10. Dry Film Imaging.- Micro-Etchants.- Compatibility With Other Processes.- Dry Film Lamination.- Exposure.- Cleanliness.- The Phototool.- Exposure.- Developing.- Solvent Developing Photoresist.- Spray Nozzles.- Solvent, Distillation, Reclamation, and Storage.- Fully Aqueous Resist 215 Special Considerations.- 11. Screen Printing.- Screen Printing Versus Dry Film Imaging.- What Is Screen Printing?.- Basic Components of a Screen Printing Operation.- Frames and Screen Materials.- Cleaning New Screens.- Ultraviolet Exposure Source.- Exposure Control.- Stencil and Screen Preparation.- Set-Up for Screen Printing.- Stripping the Screen After Use.- Automatic Screen Printers.- Plating Resists.- Soldermask.- Legend Resists.- Section 4. N/C Processing.- 12. Numerical Controlled Drilling and Routing.- Design Considerations.- Artwork Generation.- Artwork Inspection.- Drilling.- Numerically Controlled Routing Parameters.- References.- Acknowledgments.- 12A. Drilling Procedures.- Section 5. Plating and Other Wet Processes.- 13. Metal Thickness Determination.- Copper.- Tin-Lead.- Nickel, Tin-Nickel, Tin, and Silver.- Gold.- 14. Amperage Determination.- Geography of the Plating Pattern.- Bath Chemistry 292 Temperature.- Agitation.- Other Considerations.- Determining Amperage.- Method 1.- Method 2.- Method 3.- Notes.- 15. The Electroless Copper Process 300 Detecting Problems.- Drying Is Required.- The Need for Scrubbing.- Dwell Time in Copper.- Neutralize Caustic Residue.- Analyze Regularly.- Air Supply Required.- Think About the Board Being Processed.- Flash with Electroplated Copper.- Use Pump Agitation on Catalyst.- Keeping Fingerprints Off Panel Surface.- Rework Through Electroless Copper.- Troubleshooting Electroless Copper.- Analytical Information.- Procedures.- Maintenance Information.- How the Process Works.- 16. Pattern Plating: Copper, Tin-Lead, and Other Metals.- Daily Operating Routine.- Other Considerations.- 17. Contact Finger Plating.- Automatic Contact Finger Plating 367 Manual Contact Finger Plating.- Chemical Considerations.- Plating Tank Considerations for Contact Finger Plating.- Appearance of the Gold Deposit 381 Appearance of the Nickel Deposit.- Amperage Determination for Contact Finger Plating.- Contact Finger Plating Procedures.- 18. Resist Stripping.- Screen Printed Resists.- Photoresist.- Disposing of Spent Stripper.- 19. Etching.- The Challenges of Etching Today.- General Etching Procedures.- 20. Tin-Lead Fusing.- Hot Oil Reflow.- Problems.- Section 6. Multilayer Printed Circuits.- 21. Multilayer Processing.- General Processing Steps.- Planning the Construction of a Multilayer Printed Circuit.- Processing Operations.- Other Considerations.- 22. Etchback and Smear Removal.- Techniques for Etchback and Smear Removal.- Chromic Acid.- Sulfuric Acid.- Plasma.- Other Etchback Considerations.- Section 7. Process Control.- 23. The Laboratory.- Uses of the Laboratory.- Analytical Procedures.- Micro-Sectioning.- Setting Up Your Own In-House Laboratory.- Documentation.- Section 8. The Marketing Program.- 24. Sales Tools.- The Company Brochure and Advertisements.- The Product Line.- Certifications.- Personnel.- The Facility.- Suggested List of Sales Tools.- 25. What Sales People Should Know About Printed Circuits.- Processing and Materials.- Blueprint Reading and Difficulty Factors.- Mil-Spec Printed Circuits.- Bare Board Testing.- Appendix A: Yield Tracking: A Tool for Productivity.- Appendix B: CAD: Swift, Precise, Infinitely Repeatable, but Never Creative.- Appendix C: Soldermask Over Bare Copper: Alternatives and Manufacturing Techniques.- Appendix D: Control and Operation of Printed Circuit Plating Baths with the Hull Cell.- Appendix E: Troubleshooting the IR Fusing Process.- Appendix F: Preserving Solderability with Solder Coatings.- Appendix G: Screen Printing Is the Answer.- Appendix H: Forecasting Waste Treatment Requirements.- Appendix I: Wave Soldering of Discrete Chip Components.