PCB Fabrication Manufacturer Corporate Brochure

G R O W T H & F I N A N C I A L S T R E N G T H / C U S T O M E R B A S E

G R O W T H & F I N A N C I A L S T R E N G T H

Financially, Saturn is very strong. Our building and all of our equipment are fully paid. Saturn owns controlling interests in PCB facilities in Chicago, Cleveland, Pittsburgh, and Atlanta. Owning these other facilities improves our purchasing power, and provides a production safety net in case of a catastrophic event.Our financial strength also helps us to purchase new and technologically advanced equipment as the manufacturing market demands. Please visit our website for an updated equipment list.

C U S T O M E R B A S E

We service a wide variety of customers with needs that vary from 5 pieces to tens of thousands of pieces.Our customers’ needs range from medium to fine line technology with delivery requirements from two weeksto two hours. Judge us by the company we keep:

Delphi Automotive Systems (Automotive)

Lear Automotive Systems (Automotive)

Siemens VDO (Automotive)

Rockwell Automation (Industrial Drives Controls)

Telect (Telecommunications & Networking)

3Com (Telecommunications & Networking)

Black Box Corporation (Telecommunications & Networking)

Grand Products (Gaming)

Celestica (Contract Manufacturing)

Jabil (Contract Manufacturing)

Tyco Electronics – M/A Com (Microwave Electronics)

Memtron (Membrane Switches)

Mettler Toledo (High-Precision Scales)

C O M P A N Y C O N T A C T S

Nagji Sutariya – President/QC Manager . . . . . . . . . . . [email protected]

Ishvar Sutariya – VP Operations . . . . . . . . . . . . . . . . . [email protected]

Perry Sutariya – VP Sales . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Yash Sutariya – VP Corporate Strategy . . . . . . . . . . . . [email protected]

Jay Fredericks – National Sales Manager . . . . . . . . . . [email protected]

Syed Salam – Customer Service . . . . . . . . . . . . . . . . . . [email protected]

Saturn Electronics Corporation 28450 Northline Rd. Romulus, MI 48174 734.941.8100 See reverse.

P R O D U C T I O N C A P A B I L I T I E S / T E C H N O L O G Y R O A D M A P

P R O D U C T I O N C A P A B I L I T I E S

Our technological capability is totally customer driven. The following roadmap does not project beyond 2008because it can change at any given time.

M A T E R I A L S

Feature Current Capability Future Capabilities Today’s Products

Laminate Nominal Tg 260˚C 260˚C CEM-1

Laminate Nominal Td N/A 350˚C CEM-3

Maximum Layer Count 24 24 FR-4

Min Finished Thickness .014” .014” 170Tg FR4

Min. Core Thickness .005” .004” - .002” Lead Free

Maximum Panel Size 18” X 24” 20” X 24”

F A B R I C A T I O N

Feature Current Capability Future Capabilities Today’s Product

Minimum finished hole size .006” .006” Drilling

Blind/Buried Vias .006” .003” - .002” Routing

Routed Part Tolerance +/-.005” +/-.005” Scoring

Scoring Tolerances +/-.003” +/-.003” Punching

I M A G I N G

Feature Current Capability Future Capabilities Today’s Product

Minimum Lines/Spaces .004” .003”-.002” Photo Print

Min. Quad Flat Pack Pitch .016” .016”-.012” Plugged Hole

Minimum Pad Size .005”/side .005”/side-.004”/side Peelable Mask

Soldermask Registration .003” .002”

Soldermask Tolerance .002” .002”

P L A T I N G & S U R F A C E F I N I S H E S

Feature Current Capability Future Capability Today’s Product

Finished Copper Thickness 12 ounce Selective Finishes

Hot Air Solder Leveling Yes RoHS Compliant

Lead-Free Solder (HAL) Yes Heavy Cu

Full Body Hard Ni/AU Yes Multilayer

Immersion Gold/Silver Yes

E X A M P L E S O F C U R R E N T T E C H N O L O G Y A P P L I C A T I O N S

The exciting part of the Printed Circuit Board fabrication business is the integration and application of variousfabrication processes for the manufacture of high technology, exotic, and other non-standard products. Hereare just a few of the many examples we have at Saturn.

Fine Line and Spacing We have invested over $200,000 in software, analysis tools, R&D, and equipment to develop systems for fineline and spacing products. The current system addresses layer to layer registration issues by customizingmaterial scale factors for each specific design. Also, we use a cupric etching system, which is essential for creating fine lines on inner layers. As a result, we are currently processing 3 mil line / spacing in prototypequantities (4 mils in production) and have built boards with layer counts in excess of 20 layers!

Controlled Impedance Designs Our engineers have access to impedance design and stackup software that enables us to verify your linewidths, spacing, and stackup prior to CAM. Based on the proximity of your design to our calculations, we canmake adjustments to the design or adjust the stackup to best model the desired impedance. After fabrication,we verify our calculations by performing impedance testing using our Polar CITS500s Controlled ImpedanceTest System.

Heavy Copper Multilayer At one point in recent history, Saturn was one of North America’s largest users of heavy copper laminate,which we used in the production of power distribution boards for the automotive industry. We retained ourskill set in precision etching heavy copper and applied it to other industries, namely the power supply industry.Furthermore, we applied our registration system to address concerns such as layer to layer winding registra-tion, dry resin, and etch factors commonly seen by users of heavy copper multilayer boards. We commonlyproduce boards with 2, 3, 4, & 6 ounce copper with up to 20 layers!

PTFE / Hybrid Technologies The addition of the March plasma treatment system allows us to offer our customers PTFE (or Teflon) basedproducts. These are commonly used in designs with signal integrity concerns. Standard PCB fabricators cannot offer these materials easily due to the plasma treatment these materials typically require. In order toplate this material effectively, the surface must first be activated. We have in-house capability and materialsinventory that enables us to best serve our customers. We have also developed the proper lamination recipesthat are required to produce hybrid boards using PTFE-based and FR-4 materials together in one design.

Cavity Boards Cavity boards are multilayer designs that expose inner layers to air by requiring pockets of material to be cutout. This requires laminating precut materials, controlled-depth fabrication, tight processing controls, andmanufacturing versatility. Also, our standardized Multi-Line tooling systems have been critical in the process-ing of cavity boards.

Internal-Cavity Boards Internal-Cavity boards are multilayer designs that require air gaps in internal layers. Again, this requires laminating precut materials, tight processing controls, manufacturing versatility, and standardized Multi-Linetooling systems to manufacture cost-effectively in volume quantities.


Q U A L I T Y S Y S T E M S

Q U A L I T Y S Y S T E M S

In order to deliver the highest quality products to our customers, we have implemented several qualityAssurance and Continuous Improvement systems. Our primary goal is to maintain a robust quality systemthat emphasizes defect prevention and reduction of waste in the supply chain. Some of the salient featuresof our Continuous Improvement systems are as follows:

Quality & Reliability TestingTo ensure our customers receive product that is of world-class quality, we utilize inside and outside testingcapabilities. On a daily basis we manufacture a test panel that includes all of our capabilities. Once it is complete, we steam age the panel for 8 hours, test for solder ability, cross section all the hole sizes to verifyplating quality, and then test for Ionic Contamination. This is done on a daily basis, but every year we fabricate a daisy chain test panel and send it out for High Temperature Storage (125∞C), Temperature Cycling(-45 C - 125 C, 1000hrs.), and High Humidity (100%, 1000 hrs.). These samples must maintain less than 10%resistance and then they are micro sectioned to verify the visual characteristics. In addition to these tests,we perform extensive Ionic Contamination tests, solder ability tests, resistance to chemical tests, and Autoclave.

Quality Circles: Saturn uses quality circles to find ways to improve each production process within the plant. A team of people assembles in each area of production (not necessarily their own) and they look for areas for improvement. Brainstorming meetings are held and all feasible changes are implemented. This programallows operators to contribute towards continuous improvement programs, while gaining knowledge aboutother processes other than their own.

Kaizen:Kaizen means continuous improvement in Japanese. Utilizing Kaizen in our processes has helped us toimprove our process efficiency by eliminating waste and unnecessary motion within the manufacturing process.

Internal Quality Audits:Saturn has an Internal Audit system in place, which audits all key elements of our business quality manage-ment system every three months. The system verifies whether quality activities comply with plannedarrangements, and it also determines the effectiveness of the quality system. A group of trained personnelare assigned to conduct these audits.

Continuous Employee Certification Program:Saturn employees are not authorized to work on their own until they pass a certification program for eachprocess in which they are involved. All employees undergo retraining and recertification every six months.

Zero defect areas:Drilling, Routing, Scoring, Image, Electro-plating, Etching, and First Article Inspection are declared as zerodefect areas. A zero-defect area is a process in which a single non-conformance must be investigated to findthe source of the problem and a permanent action will be taken to prevent it from reoccurring.

Q U A L I T Y A S S U R A N C E

Q U A L I T Y A S S U R A N C E

High Reliability CertificationIn our quest to attain industry-high quality, we came across a leading automotive electronic supplier’s certification program. The certification process requires the PCB to pass a battery of tests and to meetstrict product specifications that address forward-looking industry concerns.

One example of the tests is a thermo cycling test, which is meant to simulate a PCB in the field over timeunder the most extreme of conditions. The test includes 1,000 cycles, each of which takes one hour. During each hour, the PCB is taken from room temperature to -40°C in 5 minutes. The PCB remains at that temperature for 25 minutes, and is then taken to 125°C within 5 minutes. The PCB is then kept at thistemperature for 25 minutes, after which it is brought back to -45°C within 5 minutes. After 1,000 cycles, the PCBs must maintain less than 10% resistance in order to pass. Only PCB fabricators with the most reliable of plating lines are able to pass this test. In addition to this test, this customer performs extensivehigh temperature storage, steady state humidity, surface ionic contamination, flammability, solder ability,resistance to chemical, and autoclave tests. We at Saturn are proud to say that our process has been HighReliability certified since 1999. The benefit to our customers is that 100% of our products are run throughthis High Reliability certified process!

ISO 9000:2000 / TS16949The goal for ISO 9002 is the development of fundamental quality systems that provide for continuousimprovement, emphasizing defect prevention, and the reduction of variation and waste in the supply chain.The key elements of ISO 9002 include documentation of all processes, Failure Mode Effective Analysis(FMEA), Quality Control plans, Reaction plans and Statistical Process Controls. TS16949 extends significantlyon ISO 9002 requirements by incorporating customer-specific requirements and determining the supplier’sability to meet them. TS16949 is a global replacement for QS9000 in that it aligns existing US, German,French, Japanese, and Italian automotive quality standards. We are proud to say that Saturn is NorthAmerica’s first Printed Circuit Board Manufacturer to achieve this worldwide recognized quality standard. Infact, as of January 2006, Saturn remains the only Printed Circuit Board manufacturer to have been awardedthis certification. Saturn has been ISO 9002 certified since 1995 and TS16949 certified since 2003 and willcontinue to pursue further quality certifications.

ISO14000Our commitment to the environment is just as strong as our commitment to quality. As such, we pursuedand were awarded ISO14000 certification in 2005. ISO14000 is a system dedicated to the reduction of wastein the process and issued to the environment. This system requires strict adherence to local and federalenvironmental regulations, recycling programs, and documented procedures. All of these activities result in a “greener” organization that is committed to social and environmental responsibility.

AS9100AS9100 defines additional areas within an aerospace quality management system that must be addressedwhen implementing an ISO9001:2000 based quality system. Typically, these requirements are included within robust aerospace quality systems.


C E R T I F I C A T I O N S


M I N O R I T Y C E R T I F I C A T I O N

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Process Description Industry Standard Saturn Electronics PCB Supplier 2 Top Score

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Copper Laminate (base material)

Drilling

Image Room

Imaging / Exposure

Plating Through Holes (PTH)

Standard sheet sizes that aresheared to size in-house.

Drilling machine that requirestools to be changed manually.Maximum panel sizes are typically 18” x 24”.

Enclosed room.

Customer artwork is alignedmanually by eyeballing theregistration of the film to thedrilled panel.

Manual dip tanks capable of5:1 aspect ratio or less.

Standard panel sizes with saw-cut edges.

This significantly reduces contamination in subsequentprocesses (e.g., imaging, testing, etc.)

Saturn also has multiple Excellon Concept 4 andCentury 2001 drilling machines. These machines are equipped with larger table sizes that enable us to drill panels up to 20” x 28”. This will reduce handling per piece in subsequent processes.

Also, these machines are equipped with automaticmeasurement systems that measure drill bit length,diameter, spindle runout, controlled-depth capabili-ties, and broken drill bit detection. Essentially, thesecapabilities remove the human element from thesedrilling issues, thereby minimizing the chance ofoperator error. Furthermore, these are essential forproducing high reliability microvias.

Saturn has a Class 10,000 Clean Room.

The environment in this room minimizes foreignmaterial from creating common shorts in the imagingprocess. Also, strict temperature and humidity controlsprevent distortion in the customer artwork.

Saturn uses MultiLine equipped drawers for imaging.MultiLine tooling removes the human factor involvedin lining up the bottom film to the top film. This resultsin significantly reduced off-registration issues.Saturn also employs the use of an Olec AX-28 auto-matic exposure unit that uses cameras to align thetop and bottom artwork. This machine can hold registration as tight as +/- .0005 mils front to back.

Saturn has built a custom automatic plating linethat has been designed and constructed primarilyin-house. The intent was to minimize plating varia-tion, which is the main goal of production plating.This was accomplished by including the following:

1. It houses racks that only allow panels to be plated one-high.

2. Anode-to-anode distance is 28 inches (maximum allowable distance for plating).

3. Water-submerged positive cathode contact.

4. Chemical-submerged anode bars for positivecontact.

5. Eductor system. This utilizes a high-volumechemical flow parallel to the panels instead of air to accomplish chemical agitation.

6. Mechanical agitation to allow chemical to flowthrough holes.

7. Dual-sided rectification to equalize copper plating from one side of the rack to the other.

8. State-of-the-art rectifiers (two per rack) with0.5% maximum ripple effect.

9. Panels are now being plated at 17 amps persquare feet (ASF), versus an industry standard of 30 ASF. This will result in more uniform plating, albeit lowered production.

10. High ductile plating process that meets C7000specs for 1,000 hour cycle tests.

11. Chemistry has been revised so that high-aspectratio plating can be performed. Both lines arecalibrated to plate 10:1 aspect ratio as a standard.

Saturn has combined all three steps into one conveyorized line. Saturn is capable of producing4 mil line/spacing in production quantities.

Instead of using a chemical cleaning process that

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Saturn Electronics Co

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Strip-Etch-Strip

Cleaning prior to LPI

Liquid Photo-Imageable Soldermask

LPI Image

Conveyorized line that iscapable of producing 7 milline/spacing.

Manual dip tanks or small conveyorized chemical cleaning line.

Manual tables or AutoRollmachines.

Customer artwork is alignedmanually by eyeballing theregistration of the film to the drilled panel.

may increase ionic contamination and compromisethe surface finish, Saturn utilizes a PumiceScrubber to clean boards prior to LPI. This processuses a volcanic ash mixture and soft nylon brushesto remove copper oxidation.

Saturn uses 4 DP-model LPI applicators to be usedin lieu of AutoRoll soldermask applicators. For stan-dard products, Saturn also employs the use of anArgus spray coating machine. This will result in lesssoldermask within holes and eliminates dimplemarks on the board surface.

Saturn uses MultiLine equipped drawers for imaging.MultiLine tooling removes the human factor involvedin lining up the bottom film to the top film. Thisresults in significantly reduced off-registration issues.Saturn also employs the use of an Olec AT-30 auto-matic exposure unit that uses cameras to align thetop and bottom artwork. This machine can hold regis-tration as tight as +/- .0005 mils front to back.

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Process Description Industry Standard Saturn Electronics PCB PCB Supplier 2 Top Score

Saturn has conveyorized the developing, final baking,and cleaning processes into a single production line.This should improve quality through reduced handlingand utilizing higher-end machinery.

Our developing line is constructed of a single-chamber,stainless steel developing line.

Saturn has installed a Bassi Tunnel oven to performfinal baking. Since heat is uniformly applied to theboards and the machine controls the cycle time,quality is improved dramatically.

Saturn has a Chemcut XL547 conveyorized cleaning line.

Saturn uses Lantronix model TT30 hot air levelersfor both Tin-Lead and Lead-Free HAL. The TT30 wasdesigned to hold panels at a 45º angle to allow thesefinishes to be used on higher density applications.

Saturn has custom fabricated a high-pressure, high-temperature post-cleaner for use after theHASL process.

This is a stainless steel post-cleaner unit that runsat 150˚F, sprays regular and D.I. water at 1 to 1.5 gallons per minute at 50 psi using 7.5 HP pumps(1/2 gallon per minute, 20-30 p.s.i., 1.5 HP is thebest available on the market). Furthermore, thecleaner uses 8-1” wide toothbrush-type agitatingbrushes versus an industry best of 4-0.5” brushes.This custom process has been proven to removeionic contamination from the surface of PCBs towell below industry standards.

Saturn augments its visual inspection process byutilizing visual inspection equipment. This equipment(hole checker) checks for holes that have beenplugged by the HASL and LPI processes, incorrectlyplated or non-plated holes, and drilled with incorrectdrill bit sizes.

Saturn offers a variety of testing alternatives.

First, Saturn has 5 Mania double-sided testingmachines.

The fixture cost for these testers is half the cost orless than those used in more traditional clam shelltesters since we build everything in-house.

Also, Saturn utilizes six flying probe testers forsmaller and prototype orders. This allows the customer to forego the cost of a hard testing fixtureand, instead, pay a modest testing fee.

Saturn has installed a washer in its shipping department that uses de-ionized (D.I.) water toclean the boards. D.I. water results in a cleanerboard, but more importantly it further removes ioniccontamination that may have occurred after HASL.

All of Saturn’s processes incorporate duplicateequipment so that in the case of an equipment failure, Saturn’s production capabilities will not becompromised.

Furthermore, Saturn has controlling interests in fourother PCB facilities so that in the event of a catastrophicevent, the supply chain will not be compromised.

Saturn has grown from a technology standpointexponentially since 2003. In-house capabilitiesinclude laser drilling, laser routing, PTFE plasmapreparation, Plasma treatment and etchback, andspecial project groups to assist customers with crit-ical and technologically demanding products.

.002”

.003” / .003”

ISO 9000, TS16949, Delphi C7000, ISO14000, AS 9100

$0 Bank Debt, $0 Accounts Payable, $0 LeaseObligations

Standard conveyor that is separated from baking andcleaning lines.

Manual conventional ovens(usually Grieve model).

Manual dip tanks.

Vertical HASL.

LPI Cleaning line is also usedas a post-cleaner.

Visual inspection by personnelusing a light table.

Either clam shell tester or single flying probe.

LPI Developing

Final Baking

Cleaning

Hot Air Solder Leveling (HASL)

HASL Post-cleaner

Inspection

Electrical Testing

Cleaning after Routing

Duplicate Processes

Advanced Capabilities

Minimum Hole Size

Minimum Line/Spacing

Surface Finishes

Quality Certification

Financial Liabilities

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Washer using city water.

Due to cost constraints, manyPCB shops will not have duplicate processes.

Minimal / Outsourced

.015”

.007” / .007”

HASL

No Certification is viewed asstandard

No standards available

Printed Circuit Board Manufacturers

A P R O V E N L E A D E R I N Q U A L I T Y, R E L I A B I L I T Y A N D S E R V I C E

28450 Northline Rd. Romulus, MI 48174 734.941.8100 734.941.3707 (Fax)

HASL, Lead-Free HAL; Immersion Silver, ENIG and Hard Gold

PCB Fabrication Manufacturer Corporate Brochure

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