1. cicorel SA Printed Circuits Manufacturing Out of Standards

2. cicorel SA LECC Heidelberg14 September 2005 Out of Standards Printed Circuits Manufacturing A User : CERN 1211 Geneva 23 Francois Vasey, francois.vasey@cern.ch A Manufacturer : Cicorel SA, Route de l’Europe 8, 2017 Boudry (Swiss organization) Anne-Sophie Golsong-Roosdorp agolsong@cicorel.chagolsong@cicorel.ch Hans Wyss hwyss@cicorel.chhwyss@cicorel.ch

3. cicorel SA LECC Heidelberg14 September 2005 Real facts in 3 specific projects Consequences as result from different perspectives (user and manufacturer) Manufacturer recommendations Out of Standards Printed Circuits Manufacturing

4. cicorel SA LECC Heidelberg14 September 2005 Readout electrodes for the Atlas electromagnetic calorimeter These 7000 electrodes in a size of 0,8 x 1,8 m had as main characteristics : Large flexible circuits etched on copper-polyimide laminates 3 layered circuits needing impeccable bonding over large surfaces in an autoclave Stringent dimensional tolerances (~ 0,2 mm over 1,8 m) for etched images and mechanical cut-outs Serigraphy of resistive ink over large surfaces Fault-free electrical properties (high voltage and connectors)

5. cicorel SA LECC Heidelberg14 September 2005 Readout electrodes for the Atlas electromagnetic calorimeter

6. cicorel SA LECC Heidelberg14 September 2005 User Based on prototypes’ production Costs : only 1 supplier for base material Simplified qualifications 1 source = 1 contact 1 type of product : developer’s knowledge and requests (Radiation properties). Manufacturer Larger format : Production’s requirements ≠ selection of the material supplied Quality needed not provided by selected supplier Doubts in solution and in feasibility, doubts in technology, doubts by engineers Consequences Both developer and manufacturer agree on specification criteria Homologate and certify materials and suppliers Consider long delay and loss of time and money Manage production quality and logistic. Planning. Readout electrodes for the Atlas electromagnetic calorimeter

7. cicorel SA LECC Heidelberg14 September 2005 The hybrid to be delivered consists of a 6 layer copper/polyimide flexible circuit, laminated onto a carbon-carbon substrate. It is equipped with SMD components and with ASICs which are wire bonded ATLAS SCT Endcap Hybrid K5.2 Assembly

8. cicorel SA LECC Heidelberg14 September 2005 K5.2 THERMAL DRAIN

9. cicorel SA LECC Heidelberg14 September 2005 K5.2 Hybrid Assembly User Need of thermal drain Use of new technology, material Carbon, best technological features for thermic and functionality aspects Complex format Test data record Manufacturer Complex format to be easily metalized Fragility of selected material Focus on an automated solution Interface and requests between several involved industries (PCB manufacturer and assembler) Consequences Manufacturer to understand with anticipation the needs and application of user for the data record. Define a project leader. Adapt manufacturing constraints and think of final solution. Consider industrialization. Time for Engineering and Conceptual phase.

10. cicorel SA LECC Heidelberg14 September 2005 Quench Heaters for LHC superconducting magnets The Quench Heaters consist in partially copper-plated austenitic stainless steel strips sandwiched between electrically insulating (Polyimide) foils with electrical and mechanical properties so as withstands high voltages, low temperatures, high compression forces and ionizing radiation

11. cicorel SA LECC Heidelberg14 September 2005 Quench Heaters for LHC superconducting magnets

12. cicorel SA LECC Heidelberg14 September 2005 Quench Heaters for LHC superconducting magnets User Heating capability Base material to be homologated under specific conditions After several lots : new specifications on the stainless steel Manufacturer No possibility to fulfill all Quality tests on stainless steel Specifications ≠ Standard Approval of manufacturing lots causes delays Delivery times are not respected Consequences Specifications are adapted Manufacturer works in defined conditions but faces performance and quality challenges Assure contractual conditions Make attentive to best case, worst case at an early stage

13. cicorel SA LECC Heidelberg14 September 2005 Manufacturer Recommendations Technology driven projects should involve early, a team of experts, where each step of realization and manufacturing are represented. Research-Development (with different industries)- Product management-Testing-Implementation. Define a team with a project leader, open and multi skills Always think best case, worst case. Find agreement with all parties involved. Be aware that a theoretical solution needs an industrializing expertise and consideration

14. cicorel SA LECC Heidelberg14 September 2005 Manufacturer Recommendations Consider intermediary Quality controls in manufacturing processes (quick failure reactions, statistics, preventive actions) Consider time for prototypes and corrective actions before definitive launch Guarantee base material continuity standard Maintain constant communication and working teams