1. StencilScan™

2. Process Control & Inspection, Products for the Electronics Industry
Assembly Programming,
Reverse Engineering
Products for the Electronics Industry
Today we will be talking about Smart Sonic Process Control Tools for the PCB Industry and what’s new!

3. Agenda COMPANY OVERVIEW TECHNOLOGY
Introduction
Product Philosophy
TECHNOLOGY
Flatbed Scanners
Process Control
Hardware Configuration
Stencil Inspection and Data Creation Products
StencilScan
StencilScan Lite
SUMMARY

4. “Applying Low Cost, Multi-Purpose Vision Systems to the Electronics
Manufacturing Industry”
versus
High Cost – Single Function

5. Introduction ScanCAD Founded in 1990
Global Sales & Support Network
Smart Sonic – OEM Partner since 2001
Over 900 Customers in 46 Countries
First Systems Installed in 1987
Vision Systems
PC- Based
Low Cost, Easy to Use,
Multi purpose

6. Product Philosophy Newest Technology Applications Flexible Low Cost
Consumer driven scanner hardware platform
Customer investment protected since 1987 – upgrade path
Applications
From board design to fabrication, assembly and test
Process control for stencils, screens, artwork, printed & dispensed materials
Niche applications… no reason to reinvent the wheel..!
Flexible
Many applications on one system
In line or off line configurations
Low Cost
Best price/performance ratio in the industry
Prices range from about US$3K to $80K
Easy-to-use
Golden board or CAD programming in minutes
80-20 rule providing low false call rates

7. Inspection vs. Measurement
Inspection System Measurement System
Check 100% of Part Sample Portions of Part
Output is Pass/Fail Output is Measurement
Low Cost Higher Cost
Scanner Based Highly Accurate/Granite base
Overlay CAD and Image Point to Point Measurement
Fast Not as Fast
Multi-Purpose Single Purpose
Can Measure, but Not as Accurate Can Inspect 100%, but Very Slow
No system available that can do both…..inspect 100% and perform
very accurate measurement at a price the market is willing to pay.
Systems are complimentary…..many customers have both.
Just to make sure there is no confusion, I would like to say a few words about what we mean by inspection and how this really compares to a measurement system.
These are some generalizations and don’t hold in all cases, for example a caliper is a measurement system, but it is very low cost. But, this should give you a general understanding of the differences.
With this inspection system, 100% of the part is checked and the output is a pass fail with a list of defect locations if there are failures. With a measurement system, typically only a few sample locations are measured and the output is a measured value.
Typical high end measurement systems are very accurate with granite bases and is higher cost than the inspection systems we are talking about.
Inspection systems are faster than measurement systems.
We don’t know of any system that can do both at a price the market is willing to pay, so they are really complementary…..many customers have both.
The inspection system for 100% inspection and the measurement system to measure a few points to a highly accurate level.

8. Technology 8

9. Flatbed Scanner Technology
Existing Vision Platform
Camera, lighting, motion control “all” in one unit
PC technology product cycle benefit
Worldwide availability and support
Excellent price/performance ratio
Low risk – not proprietary hardware
Very High Resolution
200 – 12,800 dpi, Color or B&W
A3 size scan area – inspect up to 800 X 800 mm
Accurate
Calibrated system with glass plate
Software performs self diagnostic test
Robust Hardware
Small footprint
High MTBF
“…a very smart package”

10. Scanner Evolution (1990 – 2010) 1 Model E24 Scanner equal to 440
True Optical Mpixels Total
Year Scanner Resolution(DPI) per sq. in MPixels
1990 Model F x
1998 Model E x
2001 Model E x
2004 Model E x
2006 Model E32 (A4) x
1 Model E24 Scanner
equal to 440
5 Mpixel Cameras!

11. Process Control Philosophy
Catch problems BEFORE production floor – PRE-Production
Design (holes, slots, real estate, manufacturability…)
Components (multi vendor, shape , color, size….)
Boards (multi vendor, variables…)
Stencils/screens (stretch, wear, missing, blocked or damaged apts.)
Work instructions (clear, current, precise, multi-language…)
Catch problems REAL TIME - Production
Close the loop
Direct Feedback
Watch the process
Detect trends BEFORE they reach failure
In-line or Off-line SPC
Traceability at all steps of production, including manual operations
NO SURPRISES…!!! 11

12. Hardware Table Contact System Scanner Faces Up Part Faces Down
Dry parts or
3D & wet parts with standoff
Lighting
Top or bottom
Calibrated System
Glass plate
Programming
CAD, Gerber or golden parts

13. StencilScan™
A powerful inspection, measurement, process control and data creation tool

14. StencilScan Products Two Versions of stencil inspection products
StencilScan – Inspection and Data Creation
StencilScan Lite – Inspection Only

15. StencilScan™
100% automatic inspection of stencils and screens for absence / presence, position and size of apertures
4000 dpi allows inspection of apertures as small as 2 mils / 50 microns
Guarantee stencil & screen accuracy
Compare board to stencil prior to production
Supply production with required Gerber data
Create stencil files from boards, films and stencils
Stencil
Screen

16. Why Smart Sonic Inspection Systems?
Systems are the standard in the industry for stencil/screen/film/PCB inspection – it’s the leading system in the world!
Inspection is needed- It is not acceptable to ship or use defective film/PCB’s/stencils!
StencilScan Lite is the lowest cost complete stencil/screen inspection system in the industry
100 % inspection of stencils/screens/film/PCB versus both the original customer Gerber data and the modified Gerber cut file or a Golden Part
No limits to the maximum part size
Inspect very small features, half or partial etch features and other complex shapes
Also create or modify Gerber data to match PCB with full StencilScan
Inspection of stencils/screens/film/PCB in any material including disposable plastic or paper stencils, diazo, glass, chrome, electroform, stainless, etc
Systems are very easy to use and based on a standard PC platform

17. StencilScan™ Inspection Process
In seven quick and easy steps!
Import Gerber file
Scan stencil or screen at appropriate dpi
Super-impose scanned image and Gerber
Fine align scanned image and Gerber
Inspect automatically
Review errors
Print certification report

18. The imported Gerber is displayed in green
1. Import Gerber File
The imported Gerber is displayed in green

19. 2. Scan
The stencil or screen is scanned at the appropriate dpi and displayed in blue

20. 3. Overlay Scanned Image and Gerber
The scanned image and Gerber image are super-imposed at a common point

21. 4. Fine Align
Any remaining skew between the two images is corrected using the “Fine Alignment” function

22. 5. Inspect
The automatic inspection process offers a variety of inspection levels and options to verify aperture position, shape and size

23. 6. Review Errors
Errors are highlighted in red and sequentially numbered for easy viewing

24. 7. Print Certification Report
Add the report to any letterhead or certificate

25. Examples:

26. Partially blocked or undercut aperture flagged as an error against 6 mil (150 micron) Gerber

27. Undercut and missing 2 mil (50 um) apertures

28. WAFER BUMP STENCIL inspected in less than 9 minutes
53, mils X 10.5 mils

29. Under developed 2 mil traces (50 microns)

30. Photo Tool Inspection Check new Photo Tool vs. CAD/Gerber data
Compare to part design or photo tool design with compensation for over/under etch
Check existing Photo Tool for scratches, pinholes, damage, etc.
1 mil blockage
These defects difficult to find with a measurement tool. Need 100% inspection. 1 mil blockage defect and 2 mil protrusion
2 mil protrusion

31. Other Metal Parts - Partial Etch
Color imaging for partial etch inspection
Color background for backlighting can be used if it is necessary to distinguish between partial and full etch.

32. StencilScan™ Data Creation Process
Create Gerber files from boards, films, stencils or screens
Bareboard
Stencil or Screen
Gerber
Film

33. StencilScan™ Verification Process
Compare actual board to stencil and Gerber data
Bareboard
Stencil
Gerber

34. StencilScan™ Unique Benefits
Top or bottom light capability
Inspect step or half etch stencils
Image actual PCB for verification & data creation
Color and B&W imaging capability
Inspect stencils, screen, PCB’s, etc.
Multi-purpose system
Inspection and data creation
PC based
Low cost
Low initial purchase price
Low annual maintenance
Small footprint

35. SMT Magazine Article GOOD NEWS: ScanINSPECT VPI ROI ARTICLE:
“Using Stencil Design to Reduce SMT Defects” - SMT Magazine, April 2006  
Case Study of benefits of making a STENCIL that matches the PCB
125,000 units over three weeks to obtain the data
Board measurements made using CMM at 6 reference points
Modify Gerber data to match board
Stencil made to PCB instead of Gerber
43% solder paste defect reduction…..!!!

36. SMT Magazine Article - continued
Figure 5. Pad positional deviation measurements (mils) between a stencil and PCB prior to scaling. Relative to the original Gerber data, some pads were off by as much as 0.005”-0.006”.
Figure 6. The same X, Y pad aperture deviation after scaling the stencil to the PCB.

37. Summary

38. Smart Sonic™ Process Control Tools
Catch problems BEFORE production floor – “Virtual problem”
Catch problems REAL TIME – before failure – “Close the loop”
Eliminate REWORK
Environmentally friendly
Maximize existing capital investment
Reduce operator, engineer & management stress
Read bullets
- Main benefit of systems is to eliminate surprises. Find problems before production. Errors are costly on the production floor or at warranty returns or recalls. Virtual problems are much less expensive
Eliminate SURPRISES…!!!

39. Smart Sonic Systems Proven - 900+ Systems Installed in 46 Countries
Economical - Low Cost Systems - Quick ROI
Easy to use - User Friendly, PC Based
Off-line - Small Footprint Desk or Desktop
In-line - Small Footprint Conveyor
Accurate - Calibrated System
Flexible - Many Inputs / Outputs
Multi-purpose - All Software on Same Platform
Powerful - 50 micron (2mil) Features
Upgradeable - Annual Releases Since 1990
Environment - Minimize Scrap and Rework

40. SMART SONIC CORPORATION 837 E. 79 Street · Cleveland, Ohio 44103 · U.S.A. TEL: +1-818-610-7900 ·
FAX: Web Site: 
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