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Applying the symmetry conditions, we nd R = sin2 R = sin2 R = sin2 Now we need to raise indices with the metric. This gives R = g R = 1 sin2 1 sin2 sin2 = 1

FIGURE 19.16 Fabrication panel layout of the consumer electronics board: (a) the original design; (b) the final layout.

TABLE 19.11 One Company s Final Consumer Board Characteristics Size No. of Layers No. of Holes Min. Trace Width Tolerance (+/ in.) Complexity Index First-Pass Yield Price Index Rel. Price

43.6 sq. in. Four layers 1,156 0.012 in. 0.003 55.8 (24.0) 96.7% 331.9 10.2%

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The metrics of assembly trade-offs relates factors of process, component selection, and test to assembly prices. Yields and rework are factored into the points of the Assembly Report Card. The point total provides an estimation of the relative prices of assembly and test.

The president of a midsized sales organization was discussing his company s products to a group of his son s friends. He explained the way the company sells to third-

Assembly Complexity Matrix The PCB assembler supplies the assembly complexity matrix. This matrix relates various process assembly and test choices that the assembler provides along with component size, orientation, complexity, and various other known qualities to the costs of providing for these design choices. To relate these qualities to the costs, the matrix allocates design points. Typical factors that affect assembly costs are:

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One-pass or two-pass infrared reflow Wave solder process Manual or automatic parts placement Odd-shaped parts Part quality level Connector placement Test coverage The ability to diagnose tests Assembly stress testing Repair equipment compatibility

By collecting all the costs associated with assembly, test, and repair and then normalizing these costs with the smallest nonzero value, a matrix such as shown in Table 19.12 can be produced.

Factors in an Assembly Complexity Matrix Pts 35 8 9 8 Highest 1 pass IR 100% auto <98% 100% Auto Pts 20 5 3 25 Middle 2 pass IR 99% 90% auto 98% 90% Brackets Pts 0 0 0 0 Lowest IR & wave solder >90% auto >90% Post solder assembly

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Example of an Assembly Complexity Matrix An example of the assembly complexity matrix is the Assembly Report Card created by IBMAustin.This complexity matrix has 10 factors that range in points from 0 to 35.The total points can affect the prices from a 30 percent discount to a 30 percent penalty. Table 19.13 illustrates this assembly complexity matrix trade-offs with design points. 19.6.2.1 SMT Assembly Report Card. The IBM Assembly Report Card s13 10 assembly trade-off factors are shown in Table 19.13. The report card was the work of many assembly engineers with the help of the accounting department.The report card was introduced in early 1990s; within two years, through the use of the report card, assembly point scores were averaging around 75 instead of the earlier 50, with its Gaussian distribution. Remember, higher scores indicate more producibility. This effect can be seen in Fig. 19.17. The scores are no longer normally distributed.

Laminates contain different reinforcement materials (woven/non-woven glass/organic fibers, expanded PTFE, etc.), resin types (phenolic, epoxy, cyanate ester, polyimide, BT, etc.), resin formulations (blended, functionality, etc.), hardeners (dicyanodiamide [dicy], phenol-novolak, cresol-novolak, p-aminophenol, isocyanurate, etc.), and sometimes filler particles (ceramic or organic). The ratio of all of these individual components can vary widely. To define a test strategy for laminates, it is important to understand the different main components of the materials as well as the conditions during manufacturing, as these will have a large influence on their properties and quality. The evaluation and qualification of a laminate material can be a quite complex task and the new requirements for lead-free processing have specifically increased the focus on the thermal characteristics of laminate materials. A number of different qualification test methods are available to the materials engineer. However, very often not all of them are relevant or necessary for the final product. At the same time, the materials engineer faces pressure to produce quick results driven by shorter development cycles and increasing product and process requirements. The organization of the test methods described in this chapter follows a proposed best-practice guide aimed to help perform full material evaluations efficiently and at the same time address the new requirements of lead-free processing. The sections allow quick decisions, especially when a number of materials are being evaluated at the same time.

Data Comparison The first step in every material evaluation is data comparison and assessment. This step may already allow the elimination of some material candidates without performing actual tests. The first and most important thing to understand is the state of the material that is being considered. Is it an established material formulation that has a solid history at other manufacturing locations, or is it a newly developed material that has not seen mass production yet

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