This issue of The Board Authority focuses on permanent materials and the processes that are used to make them part of the board. The original intent of this issue was to focus on materials rather than process. I have long felt that the ratio of permanent materials vs. consumables in a PWB should be as high as possible. This attains the highest value-added for the ultimate purchaser while at the same time maximizing margins for the fabricator. Keep this in mind: when a laminate is used, when a hole is metalized, when a solder mask or conformal coating is added to a PWB, that material stays with the board. These permanent materials continue to add value to the board for its full life cycle; they stay with it, becoming part of the final device. Consumable materials, those consumed during the manufacturing process, where an effect is seen in the finished product but the materials themselves are consumed and no longer remain as part of the device, certainly add value. In fact, most of these consumables are necessary. However, if an effect might be obtained without using up the consumable material, than a higher value ratio could be obtained.
I realize a modern day circuit board cannot be manufactured in reasonable volume without these consumable materials, at least at the present time. However, if an enterprising fabricator, supplier, or inventor succeeds in reducing the consumables used in PWB fabrication, they would enrich the industry as well as themselves. For example, imagine all the steps involved in pre-metalization cleaning, preparation, catalization, and so forth, were eliminated and you could still metalize the hole with no reduction in quality. The cost of making a board would be far lower and thus the final value-added would be higher.
I submit that the leading material suppliers in the future will be those that reduce, rather than increase, the number of steps needed to manufacture a PWB. The materials or processes that can do this will be worth more, and everyone will benefit. I will continue exploring this permanent-to-consumable ratio in the future, as I believe it has been over-looked and is far more important to the future of the industry than many realize today.
In this issue you will find a greater number of articles on emerging technologies and fewer on tried and true permanent materials. There are two reasons for this. Many of us believe that there is a process and material revolution on the horizon. Some of the materials and processes described here may be part of that revolution. In this regard, pay particular attention to the emerging technologies described by MCT and Dimensional Circuits, as well as materials described by Nelco, Rogers, and others.
The second reason is that some of the suppliers that had originally committed to provide articles were unable to do so. The reasons given were that the products they wanted to discuss were not as far along as they had hoped at this stage and/or the present state of the industry had necessitated a change in focus and thus they were not able to contribute at this time. I would especially like to thank Mike Carano of Electrochemicals for providing a needed article on hole plugging—and for doing it with only a few days notice.
Lastly, I wish to thank all of the authors. The quality of the articles and associated graphics in The Board Authority continues to set new standards. I realize that these are difficult times; those that took the time to research, prepare, and submit a completely original article for this issue at this stressful time deserve special recognition, appreciation, and kudos. I also want to thank The Board Authority staff for putting up with all my e-mails, late submissions, and opinionated comments. Now that we've gone to press, I will admit it has been an enjoyable and gratifying experience.
DAN FEINBERG |
Permanent Materials Issue