December 15, 2009
New LED Album: Aluminum PCB for Light Emitting Diode Applications
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| LED PCB |
December 1, 2009
Clemens Lasance: Thermal Management for LED Applications
November 20, 2009
Multilayer PCB
Saturn Electronics Corporation, Multilayer PCB Fabrication Manufacturer, provides high reliability and uniform wiring in order to meet the demands of our customers. In order to establish highly reliable and deliberate interconnection of electronic circuits, Multilayer PCBs are fabricated with several layers placed over each individual layer.
In order to reduce process steps, multilayer PCBs are drilled, plated, and then laminated. Interconnection between the layers is vital. As a result, multilayers are a core product. Multilayer Circuit Board functionality serves as the real estate for the end product and thus Saturn ensures that it makes a significant contribution to the OEM by being meticulous about microvias and high density interconnections or HDI.
Multilayer Registration
Layer-to-Layer Alignment
One primary characteristic is layer to layer alignment. In addition to our MultiLine tooling systems, we have purchased and implemented the use of the PerfecTest system to fine tune our process and achieve highly accurate scale factor predictions for a variety of material types and core thicknesses.

Multi-layer Imaging
Saturn has purchased and installed four Olec AT-30 automatic alignment exposure units. These units use four cameras to align artwork top to bottom, and then use panel motion systems to automatically adjust the panel position to a best fit to the artwork. Furthermore, these units have hybrid-collimated light units that ensure exposure light attacks the panel at 90 degree angles to the artwork, which is critical for fine line resolutions.
Standard: Saturn uses MultiLine equipped drawers for imaging. MultiLine tooling removes the human factor involved in lining up the bottom film to the top film. This results in significantly reduced off-registration issues.
Advanced (inner layers): Saturn also employs the use of an Olec AX-28 automatic exposure unit that uses two cameras to align the top and bottom artwork. This machine can hold registration as tight as +/- .0005 mils front to back for inner layers.
Industry-Leading (inner and outer layers):Saturn has purchased and installed two Olec AT-30 automatic alignment exposure units. These units use four cameras to align artwork top to bottom, and then use panel motion systems to automatically adjust the panel position to a best fit to the artwork. Furthermore, these units have hybrid-collimated light units that ensure exposure light attacks the panel at 90 degree angles to the artwork, which is critical for fine line resolutions.
PCB Drilling
Microvia Formation CapabilitiesWe have installed advanced drilling systems (Excellon Century 2001 and Mania Micronics 86) capable of up to 180k RPM spindle speed, which is critical for microvia formation. Furthermore, our advanced systems use linear motion technology for X, Y, and Z axis motion. This results in not only a higher throughput, but also increased registration accuracy.
Saturn’s lowest-end PCB drilling machines are Excellon Mark VI CNC drillers. All of these machines are equipped with automatic measurement systems that measure drill bit length, diameter, spindle runout, and broken drill bit detection.
Essentially, these capabilities remove the human element from these drilling issues, thereby minimizing the chance of operator error.
Saturn also has three Mania Micronics 86 drilling machines. These machines incorporate the industry’s latest linear motion technology and 180k RPM high speed spindles. The use of linear motion increases hole position accuracy from an industry standard of +/- 0.002” down to +/- 0.0005”, including in the Z-axis, which makes these ideal for controlled depth blind via drilling.
Production Plating
Standard Production and Blind Microvias
Saturn has built a custom automatic plating line that has been designed and constructed primarily in-house. The intent was to minimize plating variation, which is the main goal of production plating. To address issues with plating small and blind holes we use mechanical agitation to allow chemical to flow through holes and vibration to remove air from microvias and blind microvias.2 Mil Line and Spacing
Saturn has installed a new Hollmuller SES line. This line incorporates the latest in spray technology that minimizes chemical puddling. This is line capable to accurately and uniformly etch down to 2 mil lines and spaces.
Saturn employs two automatic electroplating lines and, as such, PTH is a two-step process. Saturn has built a custom automatic plating line that has been designed and constructed primarily in-house. The intent was to minimize plating variation, which is the main goal of production plating. This was accomplished by including the following:
1. It houses racks that only allow panels to be plated one-high.
2. Anode-to-anode distance is 28 inches (maximum allowable distance for plating).
3. Water-submerged positive cathode contact.
4. Chemical-submerged anode bars for positive contact.
5. Eductor system. This utilizes a highvolume chemical flow parallel to the panels instead of air to accomplish chemical agitation.
6. Mechanical agitation to allow chemical to flow through holes.
7. Vibration to remove air from microvias andblind microvias. 8. Dual-sided rectification to equalize copper plating from one side of the rack to the other.
9.State-of-the-art rectifiers (two per rack) with 0.5% maximum ripple effect.
10. Panels are now being plated at 15 amps per square feet (ASF), versus an industry standard of 45 ASF. This will result in more uniform plating, albeit lowered production.
11. High ductile plating process that meets C7000 specs for 1,000 hour cycle tests.
12. Chemistry has been revised so that high-aspect ratio plating can be performed. Both lines are calibrated to plate 10:1 aspect ratio as a standard.
Multilayer PCB Prototypes
Production Quality Multi-layer Boards
Saturn builds complex quick turn prototypes to production standards per IPC Class III and high reliability testing.
DeBurrer for MicroviasAddressing the industry demand for multilayer boards and microvias, Saturn installed the Ishii Hyoki DeBurrer ICN4-700 into its Romulus-based PCB fabrication facility last week. The ICN4-700 is essential for the polishing process in the manufacture of printed circuit boards. The new DeBurrer not only increases Saturn’s advanced technology capabilities for PCBs but it also improves quality and reliability while increasing PCB production capacity.
The Ishii Hyoki PCB Manufacturing Deburrer is equipped with an ultra sonic chamber specifically designed for effectively cleaning microvias. The new Deburrer increases quality by automatically measuring panel thickness and adjusting brush pressure accordingly. The result is that Saturn’s deburring process is completely independent of manual operation during bare board fabrication.
"This New Addition to our process adds a critical capability to insure production capabilites of advanced technologies"
Yash Sutariya
October 30, 2009
LED PCB Design Webinar MCPCB
October 27, 2009
Michigan SEO - Detroit Search Engine Optimization
October 21, 2009
Aluminum PCB
October 19, 2009
LED MCPCB Fabrication
Save 30% on Thermal Management PCBs
PCB Design specifications regarding Thermal Management MCPCB fabrication for LED Applications. Sign up for the LED PCB presentation and get the latest information regarding MCPCB today. In response to the end OEM concerns over the common failure mode of browning white solder mask, Saturn developed the SuperWhite LED Soldermask that can withstand not only multiple heat cycles during fabrication and assembly processes, but also while in the field. As a trusted advisor, Saturn’s DFM Engineers provide specification for the LED MCPCB that support PCB Designers in choosing materials that best suit their purpose and needs.
MCPCB F
abrication for LED Circuit Boards
Saturn's DFM Engineers provide specification for the LED Metal Core PCB that support the PCB Designer in choosing materials that best suit their purpose in this free webinar.
July 10, 2009
PCB Copper Heatsink
May 27, 2009
REACH PCB Manufacturing
Registration, Evaluation, Authorization and Restriction of Chemicals
REACH addresses the production and use of chemical substances, and their potential impacts on both human health and the environment.SVHC PCB Fabrication
REACH addresses the continued use of chemicals with Substances of Very High Concern, or SVHC. Through supplier confirmations and an audit of the Saturn PCB Fabrication process, Saturn certifies that requirements are met in REACH PCB manufacturing as well as being EU and RoHS Compliant.About Saturn PCB Quality
Saturn Electronics Corporation manufactures bare printed circuit boards that meet or exceed IPC specifications. Saturn is certified to ISO9000:2000, TS16949, UL, and AS9100 requirements. Furthermore, Saturn meets RoHS and EU compliance, and is ITAR registered.Thermal Management Metal Heatsink, Aluminum and Metallic Core
Thermal Management Boards: Metallic and Aluminum Core, Metal Heatsink Backing
Thermal Management refers to the use of one or a combination of various materials to transmit heat away from the components or operating area of a PCB to less critical areas, such as a metal heatsink backing, aluminum core, copper or other metallic core, or heavy copper plane layer. The need for thermal management in LED boards is increasing exponentially and while other PCB Manufacturers struggle to keep up with the latest circuit board technologies, Saturn Electronics is continuously improving its PCB manufacturing capabilitiesAluminum and Metallic Core PCB Fabricator
Saturn is one of the 50 largest PCB fabricators in North America, and is regularly studying new materials and methods for both aluminum core PCBs as well as metallic core PCBs in order to help save costs. Many suppliers of this technology have developed this specific niche. As a result, their customers must absorb the supplier’s entire overhead via the piece price. Saturn remains a debt-free PWB Fabricator with a strong focus on PCB prototyping through PCB production of advanced technologies. However, our facility is also constantly processing higher volumes of standard technology PCBs. As a result, our overhead is spread over a larger number or production panels and projects, allowing us to charge a fair and reasonable price to our customers that are often atypical of the high level of technology in the bare boards that we produce.Metal Core PCB
Metal Core PCB Materials
We are working with alternative suppliers to develop materials and process flows that are equivalent (or superior) to the current standard Laird and Bergquist offerings. Once this is complete, we will be able to offer you a viable alternative that will help to save on the piece price of Metal Core PCBs while at the same time reducing lead times due to widely available MCPCB materials.PCB Heatsink Registration
We have developed a process flow that allows us to utilize our existing multilayer registration system in registering the heatsink to the PCB accurately to within 5 mils prior to bonding.MCPCB Machining
We have developed different methods of machining to produce to produce high quality product using metal heatsink and metal core. These include integrating a variety of different machining tools in the fabrication of our Metal Core PCB. A smooth finish is insured by combining existing CNC machining operations as well as specialized mechanical and chemical deburring processes. Browning White SoldermaskWhite soldermask is commonly used in LED PCB applications with metal core.Aluminum Core PCB
Thermal Management
Saturn's Thermal Management Boards meet the needs of our diverse customer base from military to power and light emitting diode (LED) PCB applications.
ACPCB
Saturn Electronics Corporation, bare printed circuit board manufacturer, is working with alternative suppliers to develop materials and process flows that are equivalent (or superior) to the current standard Laird and Bergquist offerings.
Once complete, we will be able to offer viable alternatives lowering the piece price Aluminum Core PCBs (ACPCB) while at the same time reducing lead times due to widely available aluminum core materials.
Aluminum Core PCB Materials Lead Time
Saturn stocks a variety of Aluminum Core PCB material on a regular basis. We also have inventory stocking programs for individual customers to ensure that we have materials on hand for your next order. This helps to offset the typical lead times of 3+ weeks for raw materials from Laird and Bergquist.May 1, 2009
ITAR PCB
April 17, 2009
Saturn Electronics Corp., PCB Manufacturer
February 2, 2009
Saturn Electronics to Present and Exhibit at PCB Phoenix
January 12, 2009
Quick-Turn Prototype Printed Circuit Board
Quick-Turn Prototype PCBs Prototype PCB Manufacturing Saturn Electronics Corporation concentrated quick-turn capabilities make us your one-stop shop for prototype bare PC boards. In reducing the critical time-to-market requisitions of the Supply Chain, Saturn employs a disciplined service that pledges to meet your quick-turn prototype needs by delivering the required multilayer boards on time with consistent high-quality and reliability.
SEC Quick-Turn PCB Quick-Facts Guaranteed by Saturn’s 500% guarantee to cover for your costs in the event of an electrical failure Produced in the same lines that are certified for high-reliability, safety, and under-hood applications Manufactured domestically in our Romulus facility Backed by our exceptional customer service from quote-to-delivery Maximum Layer Count: 24+ QUICK-TURN PROTOTYPE CAPACITY SPECIFIC PROGRAMS DEDICATED TO QUICK-TURN We keep 30% of our capacity open strictly for quick-turn production. Once ongoing production exceeds 70% of capacity we embark on capacity expansion program to address bottleneck areas. WELL-DEFINED AND CONTROLLED PROCESSES Saturn is more than just a highly capable fabricator with excellent pricing. It is our capacity for quick-turning prototypes that meet OEM product deadlines that sets us apart. IN-HOUSE PROTOTYPE MANUFACTURING In-House Capabilities for critical processes ensure the fastest turnaround possible. Saturn has invested millions of dollars in the latest equipment to ensure capacity stays tight by staying in control and providing reliable delivery on time. FIRST ARTICLE INSPECTION Efficient In-House processes, tightly-calibrated equipment, and dedicated personnel encapsulate Saturn’s First-Article Inspection that yields 90% for prototypes and production. Saturn offers complete PCB first article, prototyping, and volume production. Verifying that the product can manufactured in accordance with the prerequisite specifications, Saturn tests the bare board through its cross-sections to ensure they are in compliance with OEM specifications. PCB PROTOTYPE CAPABILITIES DRILLING CAPABILITIES Saturn boasts one of the most impressive Drill Rooms in the entire Printed Circuit Board industry. As PCB complexity continues to demand prototypes that push technology limits and require faster and better equipment, outdated equipment stifles a bare pcb manufacturer from growing because their PCB Manufacturing Capabilities remain stagnant. VIA-IN-PAD TECHNOLOGY Via-in-pad technology involves merging a through via with an SMT pad (typically BGA pad). Putting Via-in-Pad creates space on the external layers for more routing and avoids potential shorts during assembly. The routing channel width on the internal layers will not change. The process flow for this technology adds a great deal of time and labor to the standard MLB process flow, but achieves results and component footprints that are not possible in the standard process. A bard board prototype featuring a myriad of blind vias will require a meticulous PWB Fabricator with drills of sheer precision. Saturn believes that Investing in cutting-edge technology is tantamount to handling leading-edge PCB prototypes. LASER DRILLING Saturn’s Drill Room features Excellon’s COBRA hybrid laser system, which provides the widest range of applications, high-reliability, and high through-put. With the flexibility to run a high-mix of projects allows Saturn to respond to the complexity of high-end boards requested by customer base by staying ahead of technology limits of PCB Manufacturers who haven’t invested in a laser drill. CUTTING-EDGE PCB MANUFACTURING EQUIPMENT All our equipment is new. This is especially important when fabricating prototypes as newer designs push technology limits and mandate faster and better equipment. Consistent quality is an essential ingredient in the manufacturing of PWB Prototypes. That is why we recently purchased an AOI from MANIA that is used to locate opens, shorts, and registration issues for inner layers. REGULARLY-CALIBRATED TESTING EQUIPMENT Saturn is vigorous about keeping its equipment calibrated per OEM specifications in order to maintain proper tolerances. ASPECT RATIO Plating Through Holes (PTH) lines are calibrated to plate 10:1 aspect ratio as a standard. QUALITY AND CERTIFICATIONS SATURN CERTIFICATIONS FOR SPECIAL CASES Saturn certified for Heavy Copper PCB by the UL FLYING PROBE AND BED-OF-NAILS TESTING Saturn recently added the Acceller8 Tester to its Quality and Reliability Department. Combining an Electrical Test Scanner with Loc8/Ultim8 increases the flying probe productivities by a factor of 10. FIRST ARTICLE INSPECTION First-article inspection for prototypes and production is the best way to uncover problematic areas in these and other instances. Equally important, it is an excellent indicator of how efficient a fabricator’s processes are. High first-article yields – say 90%-plus – indicate processes are well defined and controlled. Low first-article yields speak loudly that a fabricator’s equipment, personnel and practices are out of kilter. First-article problems can stem from poorly calibrated equipment, callous or untrained personnel, lack of preventive maintenance and a host of other reasons. Saturn’s Quick-Turn Prototype PCB Expertise Saturn’s obligation to fiscal prudence makes it a debt-free, financially strong Corporation allocating profit for expansion, improved capabilities, and reduced cost Saturn’s quick-turn prototype expertise is the result of its capacity, equipment, and capabilities from the continuous reinvestments in innovative equipment Established on-time delivery of high-quality, high-reliability, fully functional bare PCB prototypes and advanced Printed Circuit Board technologies keep Saturn at the Industry forefront


