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Dispense Process Inspection (DPI) is a critical component of electronics manufacturing, particularly in processes involving the application of materials such as flux, underfill, and especially conformal coatings. Ensuring the precise amount and accurate placement of these materials is vital to the integrity and functionality of electronic assemblies. Conformal coating, applied to protect electronic circuits from harsh environments, must be evenly and accurately dispensed to avoid areas of insufficient or excessive coverage, both of which can lead to product failures. The primary challenge in DPI is maintaining consistent quality across high-volume production lines while dealing with complex geometries and varying surface conditions of the components being coated.
Traditional inspection methods often fall short in detecting minute variations in the volume and placement of dispensed materials. This is particularly problematic in high-density assemblies, where precision is paramount. Manual inspection is not only time-consuming but also prone to human error, making it inadequate for the demands of modern electronics manufacturing. Koh Young’s DPI systems provide a solution by utilizing advanced 3D measurement technology. These systems can accurately measure the volume, height, and area of dispensed materials, ensuring complete and uniform coverage to protect sensitive electronic components from moisture, dust, chemicals, and temperature extremes.
Koh Young’s DPI systems use structured light projection and multiple cameras to create detailed 3D images of the dispensed material. These images allow for precise measurements and the detection of any deviations from the desired dispense patterns. For conformal coatings, this means ensuring that the coating thickness is within specified tolerances and that there are no areas of over-application or under-application. Real-time feedback from the DPI system allows for immediate adjustments to the dispensing process, minimizing defects and enhancing overall production yield.
In addition to conformal coatings, Koh Young’s DPI systems are also highly effective for inspecting other critical dispensed materials such as flux and underfill. Flux is essential in soldering processes, promoting wetting by removing oxides from the surfaces to be joined. Ensuring the correct amount and precise application of flux is crucial, as too much can lead to residue issues and too little can result in poor solder joints. Koh Young’s DPI systems can detect and measure the exact volume of flux applied, ensuring optimal conditions for soldering and preventing potential reliability issues.
Underfill is another critical material, particularly in the assembly of advanced electronic packages like flip-chips and ball grid arrays (BGAs). Underfill provides mechanical reinforcement to solder joints, enhancing thermal cycling reliability and protecting against mechanical stresses. Accurate dispensing of underfill is vital to avoid voids or insufficient coverage, which can compromise the integrity and longevity of the electronic assembly
Implementing Koh Young’s DPI solutions brings significant benefits to manufacturers. The accurate measurement capabilities ensure that materials like conformal coatings, flux, and underfill are applied correctly, leading to higher product quality and reliability. This is particularly important for conformal coatings, as even small defects in the coating can lead to significant performance issues or failures in harsh operating environments. The real-time feedback provided by Koh Young’s systems allows for immediate corrective actions, reducing the likelihood of defects and ensuring consistent quality across production runs.
In conclusion, Dispense Process Inspection, particularly for conformal coatings, flux, and underfill, is a critical aspect of electronics manufacturing. Koh Young’s DPI systems offer a robust solution to the challenges faced in this area by leveraging advanced 3D measurement technology and providing real-time feedback. These systems ensure accurate and reliable inspections, leading to improved product quality, reduced rework and scrap rates, and enhanced production efficiency. The ability to use inspection data for continuous process improvement further enhances the value of Koh Young’s DPI systems, making them an essential tool for manufacturers aiming to maintain high standards of quality and reliability in their production processes.
Learn about our Automated Optical Inspection in our education series here.
