Solutions and benefits
How to fix Flexible-PCB sourcing issues
A comparison of chemical wet etching and Dry Phase Patterning
Flex-PCB everywhere
The global flexible PCB market is expected to reach $33 billion USD by 2024, growing at a CAGR of 10.6% between 2015 and 2024. The Asian production capacity dominates and serves the rest of the world market.
As demand for Printed Circuit Board and Flexible Printed Circuit Boards grow, so do sourcing issues.
Causes of sourcing issues
- Component shortages
- Increasing prices of raw materials
- Trade conflicts
- Logistical complexity
- Covid-19 disruption
A PCB shortage can lead to
- Longer lead and production times
- Decreased production
- Layoffs
- Declining revenue
THE PROBLEM
with Chemical wet etching for Flex-PCB production
Slow and complex process
Complex logistic flow of multiple materials for processing
Corrosive chemicals
Can’t be installed in an electronic assembly environment
Environmental and sustainability issues: water, electricity, etc.
The Solution
Secure the sourcing with in-house PCB production
With Dry Phase Patterning, you can secure and shorten the Flex-PCB production process by bringing it in-house. This speeds up prototyping and production while removing an entire step from your supply chain and simplify the logistics.
Quality materials from Avery Dennison
With the DPP technology you can use various types of flex foil materials for example Al (aluminum), Cu (copper) or (CCA) Copper Cladded Aluminum as top layer. The Copper Skin from Avery Dennison Hanita is an excellent (CCA) material for sustainable products in the DPP 360 machine. Copper Skin give the cost advantages of aluminum foil with the trouble-free connectivity of copper in this innovative combination of the two.
The cliché
Embosses your desired pattern onto the web.
The web
A multi-layer material with a conductive top layer and a dielectric bottom carrier.
The milling wheel
Removes the protruding pattern from the top layer of the material while the bottom carrier remains untouched.
Chemical wet etching vs. Dry Phase Patterning
Manufacturing process
Chemical wet etching
Time elapsed: days to weeks
Multiple Raw materials
Master print
Chemical etching
Wash process
Master print removal
Quality control
Harmful waste handling
Shipping
Inventory
Assembly
Finished product
Dry Phase Patterning
Time elapsed: minutes to hours
Single Raw material
Patterning and metal removal
Quality control
Re-usable residuals
Assembly
Finished product
Lead time
The amount of time that passes between the start and end of a process.
Chemical wet etching
Long
Shipping product from overseas
Dry Phase Patterning
Short
No shipping, production handled in-house
Manufacturing costs
Costs incurred during the production of a product.
Chemical wet etching
High
High material and operation costs
Dry Phase Patterning
Low
Low material processing and operation costs
Logistics simplicity
The ease of managing how resources are acquired, stored, and transported to their final destination.
Chemical wet etching
Complex
Ordering, storing and transporting multiple materials
Dry Phase Patterning
Simple
Ordering, storing and transporting one material
Sustainability
Conservation of natural resources and the environment.
Chemical wet etching
High power consumption
Uses corrosive chemicals and a lot of water/electricity. Residuals end up as land fill. Long-distance shipping increases carbon footprint even more
Dry Phase Patterning
Low power consumption
Uses no chemicals and far less water/electricity. Metal residuals can be recycled. Decreased carbon footprint thanks to in-house production
Worker safety
Healthy and secure working environment.
Chemical wet etching
Unsafe
Corrosive chemicals
Dry Phase Patterning
Safe
Mechanical process, no chemicals
Intellectual property
Copyrights, patents, trademarks, trade secrets.
Chemical wet etching
Unsafe
Send your designs to another company for production
Dry Phase Patterning
Safe
Keep your designs in-house
Contact
CEO
Staffan Nordlinder
staffan.nordlinder@dppatterning.com
+46 708 200 811
Sales
Tommy Höglund
tommy.hoglund@dppatterning.com
+46 722 454 674
Visiting address
DP Patterning AB
Södra Grytgatan 4
602 33 Norrköping, Sweden
info@dppatterning.com
Would you like to learn more about Dry Phase Patterning?
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