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R&D

Material, Process & Technology Validation

At Starteam, we believe that quality makes the difference. In the R&D lab, it is our main focus to ensure the production processes, the material used, the end surfaces and the long-term reliability of our products – are all in the direction of zero defects.


In the single-digit DPPM range, the standard quality control during the circuit board production and the final inspection is by no means sufficient to achieve significant improvements. Rather, statistical test, evaluation methods and standardized test plate designs are required here in order to continuously measure and further improve the production process.


                   

 

Examples:  SIR / CAF / Wetting-Balance / cross-cut / layer registration / s-m registration / via reliability / layer registration



With this method, we achieve recurring and comparable test results with which optimization can be measured and compared directly. These results are therefore free of the effect that conventional PCB layouts come with.

 

These standard layouts are used to measure and continuously improve our processes, materials and defect rates, as well as potential weakness points, in cooperation with our engineers, quality experts, NPI  team and specialists in our test laboratory. 

Wetting balance system to examine and monitor the solderability of the end surfaces used, as well as the storage and aging resistance.


                                                                                                                              

                                                                                         Test Panel

 

 

With regards to lead-free multiple soldering processes, this is a key issue in the interaction of the circuit board and component assembly. 

 

In addition to our thermal shock and dump-heat test cabinets, we have invested in measuring equipment to examine and also document the reliability of the vias and the material reliability in relation to CAF and SIR under defined conditions.

 

     

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  • For this purpose, our CML test coupons are connected to the measuring aperture in the respective test cabinets or test cycles and the electrical properties are monitored and documented.

      


Product Validation & Reliability

Before going into production, a test pattern based on our customers’ original design is built and tested over a range of defined tests and simulations resembling different environments and a period of 10-15 years. Any potential defect in the test pattern will be detected and resolved before proceeding to the production stage.


With our tests, we can prove the reliability of your design over life time. If our customers' original design fails any of the tests, our engineers will investigate the root cause and reason for the failure – whether it’s a material or design problem. Together with our customers, we will provide solutions on how to improve on the design and run a new set of tests to prove the new set up. Once the design and construction is as robust as possible, we can proceed to mass production.




Example: Test Pattern



Physical Properties Tests for Customer Product Validation

 

Test projects*

Test method

Reference standard

Bow/Twist

IPC TM 650 2.4.22

IPC 600 or 6012

Thermal shock cycle

IPC TM 650 section 2.6.7

IPC TM 650 section 2.6.7

High temperature storage

IPC TM650 2.4.28.1

IPC TM650 2.4.28.1

Heat damp

IPC-TM-650- 2.6.3.3

IPC TM 650

Wetting balance test 

IPC-TM-650 2.4.14.2

J-STD-003

Thermal stress

IPC -TM-650 2.6.8

IPC 600 or 6012

Solderability test

IPC -TM-650 2.4.12

IPC 600 or 6012




Electrical Properties Tests for Customer Product Validation

 

Test projects*

Test method

Reference standard

Contact resistance

Four-wire electrical test

The resistance change must not exceed 10% compared to the initial value

SIR

IPC TM 650  2.6.3

IPC TM 650

Dielectric strength

IPC TM 650 2.5.7

IPC 6012  3.8.1 

Insulation resistance

IPC TM 650  2.6.3

IPC 6012  3.10.8

Breakdown Voltage

IPC TM 650 2.5.6.2

IPC TM 650

Hi pot test

IPC TM 650  2.5.6.1

IPC TM 650


*Not only limited to these tests