Capabilities Overview - ThomasNetcdn.thomasnet.com/ccp/01248840/42878.pdf · Geometric Dimensioning & Tolerancing Class A toolmakers averaging over twenty years experience building

Hutchinson Technology Inc. www.htch.com June 2009

Capabilities Overview Creating Value Through a Culture of Excellence

Manufacturing Expertise Hutchinson Technology has over 40 years of precision

manufacturing expertise serving the medical, defense/

aerospace, computer, and microelectronic industries. We

offer a unique combination of manufacturing expertise and

capabilities coupled with leading-edge design, test, meas-

urement, and engineering services.

Our robust manufacturing processes provide:

Precision tolerances World Class Quality (ISO 9001, 13485) Cost-effective prototypes through high volume Flexibility for material and design changes

Value-added Technologies Component assembly Photochemical machining Precision stamping and thin metal forming Plating, laminating and coating Laser welding Polymer patterning and finishing

Supported with Leading-edge Capabilities Product Design including mechanical, electrical, and thermal modeling Measurement, test, and analysis labs Process development labs Tool design and manufacturing Automation, controls, and vision integration Supply chain management

Hutchinson Technology Inc. www.htch.com June, 2009

Manufacturing Capabilities Overview [email protected] 1 320 587-1900

Scope of Capabilities

State-of-the-art equipment operated by a highly skilled team of toolmakers and manufacturing personnel Progressive stamping dies utilized for piece-part or coil processing of various metal alloys and com-posite materials in typical thicknesses from 0.1 mm to 1 mm Bruderer high-speed mechanical 60 ton and 10 ton stamping presses Contamination controlled manufacturing and in-spection environments

Dimensions and Tolerances

Finished critical feature tolerances to ±0.008 mm with 1.5 Cpk minimums

Process Control & Product Quality Methods

> 1.5 Cpk process capabilities for all critical parameters/processes Environmentally controlled precision inspection lab for validating complex geometry requirements LPC and IC monitoring of outgoing product Traceability maintained to raw material level Precision measurement equipment for tooling in-spection and manufacturing process control: WYKO surface analyzer View Pinnacle (non-contact) laser measurement systems Laser micrometers Capacitive transducer thickness measurement probes Coordinate measurement machine

On-line data acquisition for statistical process con-trol and monitoring

Precision Stamping



Secondary Stamping Operations

Variable G-force mechanical/abrasive tumble deburring Proprietary electrochemical metal finishing of product in coil form Proprietary batch chemical piece-part metal finishing: For fragile products For improved cleanliness

Aqueous DI ultrasonic clean lines with automated conductivity control Ultrasonic IPA batch cleaning systems Microprocessor controlled continuous flow heat treat (bright annealing) ovens

Precision Tooling

Modular inserted tool designs employed for efficient and cost effective interchangeability and reuse Dies built using high performance materials such as D-2, CPM10V and carbide In-die electronic sensing utilized to continuously monitor die performance while safeguarding tooling components Tooling fabrication and maintenance performed by our highly skilled and experienced tool and die mak-ers using on-site state-of-the-art equipment and processes Precision fabrication equipment: Charmilles CNC Wire EDM machines calibrated to ± 1 μm Parker Majestic CNC grinder Charmilles Sinker EDM Current EDM fast-hole burner Moore CNC jig grinders calibrated to ± 1 μm Leitz Coordinate Measurement Machine (CMM)

On-site Technical Support

Multi-discipline engineering staff (design, development and manufacturing) Tool design and drafting support Controls, quality and industrial engineering Supplier quality assurance

Stamping Support



Scope of Capabilities Typical material is stainless steel (SST) and copper (Cu), however, most metals can be photochemically machined Material thicknesses start at 0.015 mm Multiple material laminates can also be processed, including SST/Polyimide/Cu or SST/Polyimide

Dimensions and Tolerances

Through-etch Features

Minimum through features are equal to the material thickness plus 0.025 mm Standard through feature tolerance is ± 0.01 mm Standard center-to-center tolerance is ± 0.01 mm Standard center-to-edge tolerance is ± 0.02 mm

Partial-etch Features

Partial-etch thickness reduction capability is available for single or multiple areas and depths Partial-etch features require a minimum reduction in material thickness of 30% Partial-etch feature standard tolerance is ± 0.006 mm, with ± 0.004 mm achievable

Photochemical Machining



Scope of Capabilities Hutchinson Technology has over 20 years of experience with prototype to high vol-ume processing of polymer materials: High volume plasma etching (easy to control, environmentally friendly) Wet chemistry etching for specific appli-cations

Aggressive and non-aggressive etching chemistries for polyimide and glass, as well as most polymeric organic materials In-house phototool generation with capabili-ties to photolithographically expose areas up to 508 mm x 762 mm Typical applications include large surface area substrates, isotropic etch, desmear, surface prep and simultaneous dual-sided etching Custom fixture design for large part size and thickness

Dimensions and Tolerances (Feature Control on 0.018 mm Thick Plasma Etched Polyimide)

Registration to optical target within +/- 0.002 mm 0.1 mm minimum feature size and 0.12 mm minimum space between features Total etch variation of +/- 0.05 mm

Polymer Patterning Support Operations Closed-loop control of all etching parameters in a contamination controlled environ-ment for consistent plasma processing Optical Emission Spectroscopy endpoint monitoring State-of-the-art measurement systems and metrology capabilities Aqueous cleaning Automated part inspection capabilities

Polymer Patterning



Scope of Capabilities Electroplating: Copper, Nickel and Gold Electroless Plating: Nickel Pattern plating with photoresist Vacuum deposited seed layers for plating on non-conductive substrates Soft, Pure Gold: Best in class for wire bonding or solder bonding

Dimensions and Tolerances Typical thickness: 0.1 µm to 20 µm Typical thickness tolerance: ±10% to ±50% of target Product size: 1 mm to 600 mm Plated vias down to 0.1 mm (outside diameter of copper pad)

Process Control & Product Quality Methods Real-time monitoring and control of plating bath chemistries and process conditions for superior product quality Thickness control: XRF Bondability and cleanliness: solder wet-ability, XPS and gold ball shear Plated film integrity: heat and humidity stress test, porosity, bending and stress-strain test Plated film characterization: grain size and structure optimization using focused ion beam (FIB) cross-sectioning Plating thickness uniformity: thickness uniformity optimization using COMSOL FEA modeling

Plating Support Operations Engineering development capabilities for optimized surface finish, cost and performance World class analytical chemistry lab for control of contamination levels (exceeding industry standards)

Current Density FEA Model

Plating Technologies


HTI Precision Tool Manufacturing [email protected]

1 320 587-1907

Hutchinson Technology’s tooling operation was created to design and build very precise tools and fixtures with the shortest lead-times possible.

� HTI’s tooling operation includes over 100 engineers, technicians, toolmakers, machinists and designers and is located in our environmentally controlled facility with support from a satellite tool room in Plymouth, MN

� More than 10 years experience in solid model design with Pro-E, SolidWorks, AutoCAD and ANSI Y14.5 Geometric Dimensioning & Tolerancing

� Class A toolmakers averaging over twenty years experience building precision cutting, forming, fixturing and measurement tools for materials as

thin as .0008 in (20µm)

� Complex multiple component assemblies with location tolerances to .0002 in (5 µm) and multiple

independently moving components timed to 50 µin (1.3 µm) using carbide, stainless steel, tool steel, and other materials including plastics

� 7x24 operation, flexible scheduling system, and integrated tool design and build organization allow industry leading turnaround times

Tooling Operation Overview

� HTI’s focus on precision is supported by a dedicated, environmentally controlled precision inspection lab, capable of validating complex geometry, size, location and finish requirements to sub

40 µin (1µm) accuracy

� Comprehensive machine tool capability including: • Wire and sinker EDM • CNC milling, grinding, and jig grinding • Heat treat, passivation, and laser

engraving • Calibrated inspection equipment



1 320 587-1907

Precision micro-machining allows for the production of complex piece part geometry with extremely tight tolerances.

Capabilities

� CNC milling of 3D contours with internal radii as small as .003 in (76 µm) and drilling as small

as .002 in (51 µm) diameter

� Milling of carbide to 6 µin (0.15 µm) Ra surface finish with no adverse material or surface effects

� Positional, profile and size

tolerances to 50 µin (1.3 µm) and

roundness to 25 µin (0.6 µm)

� Machine spindles are measured for error motions per ASME standard B89.3.4M and

stages are regularly laser calibrated per ISO 230-1 to within 40 µin (1 µm) linear positioning as part of our preventative maintenance and calibration process

� Wire EDM profile, size and location tolerances to .0002 in (5 µm) and tighter with wire diameters from .0008 to .010 in (0.02 to 0.25 mm)

� Extensive carbide WEDM experience with surface finish capability to 3 µin (0.08 µm) Ra

Micro-sized Machining

Mating punch and die for shearing of .0008 in stainless steel

Precision multi-axis milling



1 320 587-1907

HTI uses a variety of 3-D modeling software for quick turn around design and compatibility with customer’s documents. Our systems provide easy creation of graphic files for use with our specialty machining equipment.

Software:

� Pro-Engineer

� SolidWorks

� Autocad

Print Control

� Pro-E (*Pro Intralink)

� Autocad (*AutoEDMS)

Capabilities

� Rapid 3-D modeling

� ANSI Y 14.5 GDT compliant

� File conversion capabilities such as DWG, IGES and DXF

� Video networking capability for remote design reviews

� Same day response to design related questions

� Over 10 years of experience designing with solid models

Tool Design



1 320 587-1907

With many years of experience, HTI’s toolmakers assemble, time, and fine tune precision cutting,

forming, fixturing and measurement tools for materials as thin as .0008 in (20 µm). And we have the fastest turnaround time in the industry.

� Class A toolmakers with an average of over twenty years of experience

� State certified apprenticeship program

� Concurrent design and build capability allows for rapid prototypes

� Ability to build from solid models and interpret GDT

� 7x24 operation and flexible scheduling system provide short leadtimes

� Multiple component assemblies with location tolerances to .0002 in (5µm) and

multiple independently moving components timed to 50 µin (1.3µm)

� Experience in build of tools for contamination controlled manufacturing environments

� Capable of processing a wide variety of materials with extensive experience in tungsten carbide and stainless steels

Tool Build

Documents

Capabilities Overview - ThomasNetcdn.thomasnet.com/ccp/01248840/42878.pdf · Geometric Dimensioning & Tolerancing Class A toolmakers averaging over twenty years experience building