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Basically, it is possible to produce the standard constructions of single- and double-sided flexible circuits and multilayer rigid/flex for small volume if there is a set of manufacturing facilities for multilayer rigid circuit boards However, it is not easy to achieve high productivity, with high process yield, for volume production of flexible circuits using these facilities, as they are not designed to deal with the unique issues of flexible circuits, such as their thin, flexible material Therefore, manufacturing facilities for high volume flexible circuits must be designed to take advantage of these differences, including specific equipment and process conditions, as discussed in this chapter Table 631 shows the specialties for processing the flexible circuit materials Most of the issues are caused by their complicated structures and fragile materials The coverlay structures and the stiffener constructions require supplemental manufacturing processes, making process yields lower.

The varieties of outer shapes make material yields and productivity lower Thin, fragile materials can easily incur serious mechanical damage due to rough handlingThin materials can also undergo significant dimensional changes in the manufacturing processes They cause a pattern shift between the processes and make the process yields lower High-level automation has basic barriers, discussed later, when applied to the manufacturing process for flexible circuits, because of its unstable materials Many processes must be conducted by manual methods, which are, of course, labor intensive Process elements particular to flexible circuits are required to achieve a high manufacturing yield Also, an appropriate total process design is required to achieve high productivity with high yield A roll-to-roll (RTR) manufacturing system is a high-productivity solution for volume production of flexible circuits.

However, the RTR lines are not flexible for a non-standard construction, and they are available for only the early steps of the long manufacturing processes Also, RTR processes have many limitations to apply..

High-density flexible circuits, which have been developed since the mid-1990s, have special constructions and therefore require supplemental processes. In addition, high-grade manufacturing technologies are required to generate finer circuits. Sometimes, they are called HDI

TABLE 63.1 List of Specialties for Processing Flexible Circuits Areas Special constructions Materials Issues for processing flexible materials Coverlay, stiffeners, and so on Complicated shapes Thin, low stiffness Low dimensional stability Fragile for mechanical forces Difficult for automation RTR available only for beginning

TABLE 63.2 New Manufacturing Technologies for High-Density Flexible Circuits Processes Raw materials New technologies Stable polyimide film ( 20 ppm CTE) Thin copper foil (9, 12 mm) Adhesiveless copper-clad laminates Laser (excimer, UV:YAG, carbon dioxide) Microhole punching High-accuracy x-y table Plasma etching, chemical etching Direct plating Seed layer sputtering New cleaning reagent Thin dry film ( 15 mm) Liquid resist Collimated light source, auto aligner Laser direct imaging High-resolution etchant Laser drilling Photoimageable coverlay (dry film type and liquid type) Electroless plating for Ni, Au, solder High-speed plating Laser/chemical etching Chemical etching Automatic high-accuracy punching machine Universal AOI Noncontact electrical tests Low-tension EPC system Automatic aligner with CCD camera

Copper plating Surface cleaning Etching resist Exposure Etching Coverlay Surface finishing Flying leads Guide holes Inspection Roll-to-roll system

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flexible circuits because of new termination technologies. Major items are listed in Table 63.2. Details of the processes are described in each section. Furthermore, ultra high-density flexible circuits have been considered recently as the necessary substrate materials for the next generation electronics packaging. Their circuit densities will be under 20 micron pitches with 20 micron diameter via holes. They need completely new manufacturing technologies, such as an additive process instead of traditional subtractive process. Ultra high-density flexible circuits will be considered separately.

Figure 63.1 shows the basic idea of the standard manufacturing process flow for double-sided flexible circuits, with both through-holes and stiffener boards. Basically, most of the manufacturing processes for single-sided flexible circuits are included in these processes. The first half of the manufacturing process (through pattern etching) has few choices, and the automation of the processes are relatively easy. However, the second half has many options, depending on the design of the construction. The second half consumes more labors because of the difficulties of the automation, and its manufacturing cost per unit area is much higher than that of the first half. An appropriate consideration of process design should be conducted to increase the productivity and reduce the total cost. Good process design can reduce the total cost significantly, especially for complicated constructions. Typical ideas are introduced in the following sections.