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standard weights. The cores are .004 in. (1.0 mm) or thicker, although some mass laminators are capable at .002 in. (0.05 mm); and the lamination is a single-resin system, not a mixed dielectric build. The most common construction is from epoxy resin, since most of the enhanced electrical or thermomechanical resin systems are not available in large sheet sizes. 27.4.4.1.2 Standardized Size Cut Panels. This approach is dominant in high-end technology PCBs. Some very common panel sizes are 18 24 in. and 20 or 21 27 in. The facility strives to have the fewest number of standardized panels that will accommodate the majority of the MLB sizes typical of their customer base. Tooling is then either fully fixed or modular based on those panel sizes, but other new panel sizes are not possible without new hard tooling and die. Having four to eight panel sizes is common.These sizes are based on full yield cuts from the laminator s full sheets; for example, the laminator might offer a 36 48 or 42 54 in. sheet and the fabricator orders (or cuts from full sheets) 14 18, 12 24, 18 24, and 21 27 in. panels. This system standardizes tooling into the fewest number of different sizes of hard tooling (e.g., caul plates and separator plates; see section 27.5.1.1). This approach is also best suited to advanced feature sizes, where limiting the panel size to just over the MLB size has the advantage of reducing some degrees of difficulty such as the registration requirement over a larger area. Fixed panel sizes work well for mixed dielectric builds and sequential laminations. Very large cut panel sizes such as 24 36 in., approaching mass lamination size, are uncommon but available in very high-volume or backplane fabrication specialty facilities. 27.4.4.1.3 Custom-Cut Panels. Asian fabricators have pioneered flexible custom-cut panel sizes to maximize material utilization further and so reduce costs. The difference between standard and flexible cut panels is that standard-cut panels have a limited number of predetermined sizes and consequent hard-tooling configurations, while the flexible cut panels afford a continuous range of size because the tooling isn t fixed but highly configurable. Flexible cut panels are often paired with riveting instead of pinning to hold the details, prepreg, and foil together for lamination. Many Asian facilities will offer both approaches, selecting the best suited to the job at hand. 27.4.4.2 Front-End Tooling. The first aspect of the ML-PWB tooling is commonly called front-end tooling or simply computer-automated manufacturing (CAM) tooling. (See IPC2514A, GenCAM [BDFAB], Sectional Requirements for Implementation of Printed Board Fabrication Data Description. IPC-2514 is a standard developed by the Computerized Data Format Standardization Subcommittee [2-11] of the Data Generation and Transfer Committee [2-10] of the Institute for Interconnecting and Packaging Electronic Circuits. The GenCAM format is intended to provide CAD-to-CAM, or CAM-to-CAM, data transfer rules and parameters related to manufacturing printed boards and printed board assemblies. IPC2514 is a section requirement within IPC-2511B, Generic Requirements for Implementation of Product Manufacturing Description Data and Transfer XML Schema Methodology. ) The front end is where manufacturing personnel using a CAM software package generate all phototools, the associated computer numerical control (CNC) electronic files (used by equipment such as drillers and routers), the construction stack-up, and the part manufacturing instructions, or work order, also called the traveler. The CAM station mirrors the tooling method chosen for the shop and the job s work order. The CAM software overlays the tooling pattern on each circuit layer to produce the master pattern alignment. The master artwork pattern is then photo-plotted to reproduce the artwork film tools for the imaging operations. Several important manufacturing functions fall within the bounds of the front-end tooling responsibility. 27.4.4.2.1 Design Rule Check (DRC). Design rule check (DRC) is where the electronic design data are analyzed against a specific set of fabrication rules, a virtual design for manufacturing (DFM). The capabilities and attributes of these rules are based on sound, industryproven values that match the technology targeted for construction. The default values embedded into the CAM are input by the manufacturer as technology files. These files should reflect the capability of the fabricator s equipment and processes in light of how they are utilized against the ML-PWB type being produced.
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