Planarity Check

But let’s start at the beginning: in order to be able to develop such an application at all, an extensive analysis of the material was first required. The PCBs produced by the end customer are manufactured for use in highly complex technologies such as MEMS, image sensors, optoelectronics and automotive technology. During the manufacturing process, various factors come together that make measuring the planarity of the substrates an enormous challenge: On the one hand, manufacturing requires extremely high precision in the micrometer range, which means that even the smallest deviations in planarity can affect the manufacturing process. Secondly, the substrates vary in their material composition and reflect light to different degrees, which poses major problems for conventional measuring technologies. In addition, the extremely precise drilling and cutting of the substrates is a real challenge. State-of-the-art machine technology is used to maximize the speed and efficiency of these processes without compromising on quality. However, accuracy is also of the utmost importance here, despite the changing materials.

In short, to ensure the high quality of the substrates and semiconductor components, machine manufacturer Laser Tek was looking for an option that was not only exceptionally reliable, but above all could be permanently integrated into the end customer’s systems. After several failed attempts with competitor 3D sensors, AT Sensors finally delivered a customized solution that addressed all of the customer’s challenges and was able to meet the machine manufacturer’s high standards. AT developed the C6-2040CS14-160 GigE compact sensor, which was specially designed for planarity testing in PCB and FPC production. Its advantages: its special laser, its outstanding precision and its enormous speed. The C6-2040CS uses a laser with a wavelength of 405 nm and operates in laser class 3R, which makes it particularly suitable for industrial applications. In addition, with an X resolution of 78 µm and a Z resolution of just 5 µm, it meets even the highest accuracy requirements and is also able to intelligently manage material reflectivity. Thanks to its ability to adjust the laser power, the AT sensor can deliver stable measurement results, even if the substrate material changes or is particularly reflective. Its measurement speed of 50 mm/s also provides customers with a particular benefit when processing PCB and FPC substrates.
“During the planarity test of the subtrate, AT was once again able to brilliantly demonstrate that we have a truly unique selling point in the image processing industry with our flexibility in terms of customer requirements and the innovative technology of our sensors. Thanks to our pioneering spirit and our high standards in offering our customers an optimal solution, we are always one step ahead with our products and this has proven itself once again in this case,” explains Dr. Athinodoros Klipfel, Sales Manager at AT.
To date, eight C6-2040CS sensors from AT have already been installed at Laser Tek, and a further order for 30 units is already in the pipeline. This not only shows the customer’s confidence in AT’s solution, but also that the solution is convincing in practice.
“In addition to the performance of AT’s 3D sensor, it was the company’s support that made our decision easy. In contrast to the companies we had worked with before, who always took a long time to respond, AT responded within 1 to 3 days and always provided sound solutions,” says Laser Tek. AT supported Laser Tek several times during the discovery phase directly via remote control through Anydesk to identify and resolve issues, while also providing training to the team. Above all, this proactive approach helped Laser Tek to make its production processes more efficient and minimize downtime. In addition, AT’s delivery time of around four weeks was significantly shorter than the competition, which also further accelerated the process.