Semiflex: an award-winning miniaturization success · metz-mecatech! – for the exemplary...

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Semiflex: an award-winning miniaturization success December 5th, 2018 Speaker: Andreas Schilpp

Transcript of Semiflex: an award-winning miniaturization success · metz-mecatech! – for the exemplary...

Page 1: Semiflex: an award-winning miniaturization success · metz-mecatech! – for the exemplary cooperation and the information! Semiflex is an affordable 3D technology for reliable miniaturization

Semiflex: an award-winning miniaturization success

December 5th, 2018

Speaker:

Andreas Schilpp

Page 2: Semiflex: an award-winning miniaturization success · metz-mecatech! – for the exemplary cooperation and the information! Semiflex is an affordable 3D technology for reliable miniaturization

agenda

1• The way to the champion

2• The genes of the champion

3• What may peak performance cost?

4• What's left in it? Roadmap

06.12.2018 Seite 3 www.we-online.de

Page 3: Semiflex: an award-winning miniaturization success · metz-mecatech! – for the exemplary cooperation and the information! Semiflex is an affordable 3D technology for reliable miniaturization

mecablitz M400 - „Compact and powerful.“

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system flash unit –

„Perfectly equipped, attractively packaged.“

Link

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Project „M400“

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February:First definitions forlayer stackup

April:Meeting at Metz with interdisciplinary development team

August:Start of seriesproduction

September:

leading fair

Briefing – specification

• as small as possible• Energy from 4 AA batteries

• Guide number 40 (ISO100)• perfect all-rounder for

mirrorless system cameras• as cheap as possible

Page 5: Semiflex: an award-winning miniaturization success · metz-mecatech! – for the exemplary cooperation and the information! Semiflex is an affordable 3D technology for reliable miniaturization

Design Chain electronic system development

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stated conditions Specification

„a pcb is a complex construction made out of

many different materials, produced using a variety of processes for getting tailored

functionality!“

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Größenvergleich / size comparison

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Vergleich Systeme / Comparison of systems

06.12.2018 Seite 8 www.we-online.de

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agenda

1• The way to the champion

2• The genes of the champion

3• What may peak performance cost?

4• What's left in it? Roadmap

06.12.2018 Seite 9 www.we-online.de

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The heart of the champion - the Semiflex circuit board

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„Blueprint" for

miniaturized devices with

high energy requirements,

electronics built around the

energy storage unit to save

space!

Page 10: Semiflex: an award-winning miniaturization success · metz-mecatech! – for the exemplary cooperation and the information! Semiflex is an affordable 3D technology for reliable miniaturization

The heart of the champion - the Semiflex circuit board

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Layer Stackup:

FR4Semiflex does not have flex areas, but bending areas.

no flexible material Polyimide!

no separate drying necessary

qualified for 10 bends

Bending radius and direction must be respected!

Necessary length L of the bending area is:

L = angle x radius R x Pi / 180° + 2 x 0.4mm (bevel Y)

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Big influence: layer structure and dielectric material

Prepreg constructions: not too coarse and not too fine for Semiflex!

type 106 type 1080 type 2116 type 7628

50 – 55 µm 60 - 70 µm 85 – 100 µm 180 – 210 µm

Resin and fillers

– Tg135 shows the best bending properties

– higher Tg and fillers worsen the bending properties

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Page 12: Semiflex: an award-winning miniaturization success · metz-mecatech! – for the exemplary cooperation and the information! Semiflex is an affordable 3D technology for reliable miniaturization

Designrules FR4 Semiflex

Maximum copper design

Bad: copper free area in bending zone, small

contour radius

Good: balanced copper design in bending area,

big contour radius

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Replace large 180° areas with 2 x 90° with rigid intermediate part

Regard bending direction:

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Designrules FR4 Semiflex

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06.12.2018

Reliability of construction

Bending aids: Example (left) or integrated in housing (right)

Array design + panel separation!

– Semiflex area must not be damaged during separation!

Seite 15 www.we-online.de

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How do you get a complex Semiflex in there?

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Bending and assembly tool

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Reliability of construction

idea of combined bending + fixing tools:

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Reliability of construction

idea of combined bending + fixing tools:

Does that look familiar to you?

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Gerätemontage M400 / device assembly M400

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perfect job, guys @ metz!

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Applications Semiflex Technology

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Automotive (headlights, ECU, cameras, distance measuring

technology, transmission electronics ...)

Industrial electronics (sensor technology, LED lights, drive

technology, motor control, hydrauliccontrol....)

Heavy mechanical engineering

Security technology, building services engineering (access

control, climate sensors, control and operating devices,

Smart Water Metering)

Medical technology (charger, handheld devices)

Railway technology (ECU diesel engine)

Geotechnics (Switchbox)

Page 21: Semiflex: an award-winning miniaturization success · metz-mecatech! – for the exemplary cooperation and the information! Semiflex is an affordable 3D technology for reliable miniaturization

agenda

1• The way to the champion

2• The genes of the champion

3• What may peak performance cost?

4• What's left in it? Roadmap

06.12.2018 Seite 22 www.we-online.de

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cost comparison

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Webinar from March 03, 2015:

No more cable spaghetti –

Wiring 4.0 via Semiflex

available in our Webinar Archive!

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balance sheet

100 pcs 1.000 pcs 100 pcs 1.000 pcs Remarks

a) pcb price 58,50 € 40,50 € 55,90 € 45,50 € pcbs from Europe

b) FFC cables, ZIF connectors 30,00 € 13,00 € - - EMS Sweden

c) for this SMD assembly AOI 2,00 € 1,50 € - - EMS Sweden

d) final assembly 2,00 € 1,50 € - - EMS Sweden

e) final test 1,50 € 1,00 € 1,50 € 1,00 € EMS Sweden

sum of BoM and processing 94,00 € 57,50 € 57,40 € 46,50 €

-39% -19% cost saving

additional cost factors:

f) design for

g) inventory control

h) assembly expenditure

i) test expenditure

k) stock / logistics

l) Pin- and solder connections Reliability

22 positions 3 positions

312 ZIF-contacts + 312 solder joints integrated Semiflex connection

17 components + 5 stencils 1 component + 2 stencils

5 x 1 x

6 x 1 x

rigid pcbs

with cables and connectorsSemiflexible pcb

5 pcbs 1 pcb

comparison: total system

06.12.2018 Seite 24 www.we-online.de

Page 24: Semiflex: an award-winning miniaturization success · metz-mecatech! – for the exemplary cooperation and the information! Semiflex is an affordable 3D technology for reliable miniaturization

balance sheet

100 pcs 1.000 pcs 100 pcs 1.000 pcs Remarks

a) pcb price 58,50 € 40,50 € 55,90 € 45,50 € pcbs from Europe

b) FFC cables, ZIF connectors 30,00 € 13,00 € - - EMS Sweden

c) for this SMD assembly AOI 2,00 € 1,50 € - - EMS Sweden

d) final assembly 2,00 € 1,50 € - - EMS Sweden

e) final test 1,50 € 1,00 € 1,50 € 1,00 € EMS Sweden

sum of BoM and processing 94,00 € 57,50 € 57,40 € 46,50 €

-39% -19% cost saving

additional cost factors:

f) design for

g) inventory control

h) assembly expenditure

i) test expenditure

k) stock / logistics

l) Pin- and solder connections Reliability

22 positions 3 positions

312 ZIF-contacts + 312 solder joints integrated Semiflex connection

17 components + 5 stencils 1 component + 2 stencils

5 x 1 x

6 x 1 x

rigid pcbs

with cables and connectorsSemiflexible pcb

5 pcbs 1 pcb

comparison: total system

06.12.2018 Seite 25 www.we-online.de

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agenda

1• The way to the champion

2• The genes of the champion

3• What may peak performance cost?

4• What's left in it? Roadmap

06.12.2018 Seite 26 www.we-online.de

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Semiflex constructions for special requirements

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application-specific adaptations

– The bending area is covered with coverlay

– use of mid Tg or high Tg base material (Tg150, Tg240)

Bending area with 2 copper layers

Adapted laminating technology

– improved bending behaviour

– also for thicker bending areas

– smaller bending radii

Combination with HDI

– microvia

– buried via

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www.we-online.deSeite 2806.12.2018

Z1

Z2

2Ri – xRi : Semiflexible area with 2 copper layers

for very high number of connections in the

bending area

for complete reference layer – impedance

matching

replacement of high pin-count connectors

and shielded cables

in this case price advantage is even

higher!

Page 28: Semiflex: an award-winning miniaturization success · metz-mecatech! – for the exemplary cooperation and the information! Semiflex is an affordable 3D technology for reliable miniaturization

2Ri – xRi : Semiflexible area with 2 copper layers

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Summary

Congratulation and many thanks to the company

metz-mecatech!

– for the exemplary cooperation and the information!

Semiflex is an affordable 3D technology for reliable

miniaturization solutions.

Semiflex solutions are always project-specific!

– We will be happy to advise you!

More information in our webinar archive!

Event note:

AltiumLive, Munich, January 2019 - "Digital Standards for

EDA-Tools" presented by Andreas Schilpp LINK

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Thank you very much for your attention! Questions?

06.12.2018 www.we-online.com