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Universal Instruments’ Advanced Process Lab Provides 30 Years of Research, Analytical and Assembly Services to Solve Challenges, Develop Emerging Technologies

In today’s high-tech industries, knowledge makes the difference. Founded more than 30 years ago, Universal Instruments’ Advanced Process Laboratory (APL) leverages extensive process and materials expertise to address current and next-generation technology challenges and maximize competitive advantage. The APL offers comprehensive research, analytical and advanced assembly services that enable manufacturers to realize rapid product introduction, maximize yield and optimize reliability. The APL also plays a leading role in the greater electronics community, organizing research consortia and building partnerships with academic and industry experts to identify and develop new and emerging technologies – those that will take electronics assembly far into the future.

 The APL provides three key services: Advanced Technology Assembly Services, Analytical Services and AREA Consortium.

Advanced Technology Assembly

Assembly process performance is crucial to profitability and market reputation. Whether a customer is looking to refine their current processes or effectively integrate new products, Universal’s APL will implement the best possible design, development and volume production solution for their specific challenges. 

Next-generation applications such as flip chip, SiP and PoP are not a problem for the APL. Its experts will maximize efficiency, throughput, yield and quality, ensuring targets are met quickly and quality products consistently are brought to market.

Benefits of the APL’s Advanced Technology Assembly services include:

• State-of-the-art, in-house production lines to build a full range of complex products

• Prototyping and development, first article build, NPI, volume production

• Optimized assembly solutions (design, materials, process, pioneering equipment technology) for new and existing products

• Design for Manufacture (DfM) and Design for Reliability (DfR)

• Valuable for OEMs, CEMs, suppliers, end-use consumers

• Process transfer, on-site integration, training

• On-site process audits and support, including startup

Analytical Services

Quick response to production or field failures is critical to a successful business. Reacting swiftly and decisively secures your reputation and resolves issues that otherwise can destroy profitability. To achieve this, however, you must locate and rectify the root cause immediately – a big task when working with advanced components, materials and processes. You need specialized tools to examine cost-sensitive assemblies and the expertise to correctly interpret the results.

Universal’s APL Analytical Services provide all that and more with precision analytical tools and a team of experts whose collective knowledge spans the full range of leading-edge packaging and assembly technologies.

The APL has developed critical manufacturing processes for all component families. It builds on the company’s expertise in helping customers shape ideas into products. Additionally, it actively participates in product development and design activities. “Our experience positions us to deliver failure analysis that adds real value to your business,” said David Vicari, director of the APL. This includes identifying and rectifying the root cause of the defect, increasing production yield, improving field reliability, providing evidence to support product liability cases or vendor returns, and delivering rapid return on investment (ROI).

 Valuable for OEMs, CEMs, suppliers and end-use consumers, the APL provides root cause failure analysis (component packaging, second-level interconnect, handling, final assembly); component-level interconnect/PCB failure analysis; materials evaluation (conformance, composition); reliability tests (mechanical, environmental, vibration, shock); and detailed technical reports to support findings. Users leverage the knowledge gained from the lab’s process materials and reliability research. Additionally, the APL provides detailed analysis of sample packages, including characterization of inherent weaknesses and recommendations to enhance product lifetime and yield.

AREA Consortium

More than 20 years ago, Universal Instruments’ SMT Laboratory initiated a pre-competitive cooperative research effort with various Fortune 100 companies for the comprehensive development of the assembly processes for ultra-fine pitch and tape automated bonded components. The project was organized to defray the high costs and associated technical risks among a large group of principals and to allow the researchers from the member companies an opportunity to cooperate in research projects. This highly successful research collaboration has evolved and adapted to the ever-changing demands of the electronic packaging and assembly industry.  It developed into a series of funded research projects now known as the Advanced Research in Electronic Assemblies (AREA) Consortium.

Today, the Universal Instruments AREA Consortium is comprised of leading companies in the electronics assembly industry. It’s not the usual “work-in-kind” consortium where members conduct research and group decisions are made during committee meetings. In the AREA Consortium, a team of experienced scientists conducts fast-paced research and reports back results at regularly scheduled meetings throughout the year, as well as posts research results on this website for on-demand access. All research is conducted in the Universal Instruments Advanced Process Laboratory and takes advantage of the lab’s comprehensive production and analytical equipment set. Member companies are invited to participate in the research as they see fit.  Some chose to keep resident employees in the laboratory for periods ranging from days to years.

The goal of the Consortium is to develop a fundamental, mechanistic understanding of the materials and processes utilized in electronics assembly, with special focus on maximizing assembly yields and long-term reliability. Each year, research goals are established by continual consultation with current and potential Consortium members, as well as other industry and academic researchers, guaranteeing research that takes full advantage of current knowledge.

 Each year, the APL chooses a set of relevant projects on new and emerging technologies based on consultation with consortium members, as well as other industry and academic researchers. The APL then conducts analytical and experimental research on these topics in order to generate applicable knowledge for specific product development and manufacturing processes.

The APL has earned global respect as a valuable knowledge resource, helping manufacturers worldwide to enhance yield, achieve continuous process improvement, and optimize product reliability and lifecycle. The APL addresses design, layout, process and reliability concerns to ensure comprehensive solutions to today’s – and tomorrow’s – manufacturing challenges. Vicari concluded, “It is true that in today’s high-tech industries, knowledge really does make the difference. The APL is positioned to deliver the expertise needed to maximize our users’ competitive advantage.”

For more information about Universal Instruments’ Advanced Process Lab, contact David Vicari, Director, at 33 Broome Corporate Parkway, Conklin, NY 13748; 607-779-5151; E-mail: vicari@uic.com; Web site: www.uic-apl.com.