High-tech manufacturing

Taken by X-Loupe G20 300X lens

Semiconductor Industry

In the process of IC manufacturing, dies are bonded with the gold wires that are thinner than human hair on the substrates. The layout and the electrical connection for the wire bonding are implanted by machines controlled by programs.

When wire bonding is finished, it is required to examine the quality of the bonding and to confirm the wires are connected to corresponding positions on the substrates. Usually, quality assurance personnel adopt the electron microscopes, metallurgical microscopes, or other instruments to do the quality inspection. However, it is not easy to preserve the images during the inspection process.

Taken by X-Loupe G20 300X lens

Passive Components

In order to satisfy the needs of miniature of electronic products, it has become the market requirements for manufacturers to reduce the sizes of components. The main specifications of the passive components in the markets are 0805 and 0402, but the new specification as small as 0201 (0.6*0.3*0.3 mm) has been announced to the market lately.

The easiest way to inspect the passive components is to check the appearance of the components. If the surface is burned, it means this passive component is malfunction or in bad quality. Moreover, the examinations of the sizes, particles on the surface, and the welding of the passive components on Printed Circuit Boards (PCB) are also required. Another issue for the manufacturers of the passive components is to inspect the suppliers’ products and returned products. To solve the questioned products, it is necessary to have pictures in the documents.

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Electrical Discharge Machining (EDM)

Electrical Discharge Machining is a non-traditional machining method that is used for hard metals or metals which are difficult to shape or cut angles. EDM only works with metals that are electrically conductive. This method uses the sparks produced by repetitively electrical discharges to remove the metals. For example, in wire EDM, a very thin wire serves as the electrode to feed through the workpiece, and the workpiece is cut according programs controlled by CNC in X-Y axis.

In the process of EDM wire cutting, the operators of EDM machines need to inspect the process from the wire cutting and to adjust the axis movements to prevent errors. However, taking the workpiece out from EDM machines to be examined underneath microscopes might lead more errors due to the previous positions in EDM machines is different from the position when the workpiece is finished examination and put back later.