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Printed Wiring Board Industry: Facility Characterization
2.1 General
Facility characterization data were collected that provide a useful comparison among survey respondents and also serve as a means of relating the respondents as a group to the overall PWB industry population. These data, which include measures of facility size and production capabilities and methods, are presented and discussed in this section.
2.2 Comparison of Facility Sizes
Several measures of facility size were employed to help characterize the respondents and compare them to the overall PWB industry sector, including: annual sales in dollars, square footage of manufacturing facility, number of employees, and PWB production rate measured in square footage. These data are presented in Exhibit 2-1.
| Respondent ID |
Annual Sales ($/yr) |
Facility Size (ft2) |
Employees | Production (board ft2/yr) |
|---|---|---|---|---|
| 6710 | nr | nr | 51 | 15,000 |
| 29710 | nr | nr | 500 | 57,000 |
| 33089 | $1,500,000 | 15,000 | 30 | 200,000 |
| 947745 | 2,000,000 | 9,000 | 28 | 40,000 |
| 279 | 2,500,000 | 15,000 | 40 | 250,000 |
| 32482 | 2,800,000 | 26,500 | 35 | 75,000 |
| 36930A | 3,000,000 | 18,000 | 38 | nr |
| 44657 | 3,038,042 | 22,000 | 40 | 42,358 |
| 37817 | 3,600,000 | 14,000 | 45 | 540,000 |
| 25503 | 4,000,000 | 25,000 | 40 | 90,000 |
| 502100 | 4,500,000 | 37,000 | 65 | 60,000 |
| T3 | 6,000,000 | 24,000 | 50 | 200,000 |
| 965874 | 6,000,000 | 38,000 | 105 | 175,000 |
| 273701 | 7,000,000 | 22,500 | 80 | 280,000 |
| 959951 | 7,000,000 | 54,000 | 85 | 320,000 |
| 3470 | 7,500,000 | 30,000 | 100 | 240,000 |
| 953880 | 9,000,000 | 30,000 | 100 | 180,000 |
| 41739 | 9,000,000 | 31,800 | 130 | 300,000 |
| 43841 | 11,000,000 | 56,000 | 115 | 250,000 |
| 44486 | 14,000,000 | 36,000 | 150 | nr |
| 42692 | 15,000,000 | 50,000 | 150 | 360,000 |
| T2 | 16,000,000 | 30,000 | 175 | 600,000 |
| 955703 | 16,000,000 | 112,500 | 150 | nr |
| 955099 | 16,000,000 | 100,000 | 250 | nr |
| 36930 | 17,000,000 | nr | 200 | 96,000 |
| 358000 | 18,000,000 | 36,000 | nr | 500,000 |
| 462800 | 20,000,000 | 55,000 | 210 | 3,750,000 |
| 237900 | 22,000,000 | 300,000 | 178 | 273,000 |
| 43694 | 24,000,000 | 42,000 | 450 | 500,000 |
| 133000 | 36,000,000 | 125,000 | 366 | 600,000 |
| 42751 | 40,000,000 | 50,000 | 380 | 540,000 |
| 31838 | 45,000,000 | 300,000 | 480 | 3,000,000 |
| 107300 | 50,000,000 | 200,000 | 350 | 5,000,000 |
| 55595 | 50,000,000 | 109,000 | 420 | nr |
| T1 | 51,000,000 | 70,000 | 550 | 936,000 |
| 946587 | 84,000,000 | 120,000 | 500 | 1,900,000 |
| 740500 | 100,000,000 | 600,000 | 1,000 | 1,800,000 |
| 3023 | 105,000,000 | 190,000 | 830 | 2,300,000 |
| mean | $23,012,168 | 85,523 | 223 | 771,799 |
| median | $14,500,000 | 38,000 | 150 | 290,000 |
nr = no response
In terms of dollar sales, the survey results indicate that the respondents span the range of facilities found in this industry sector, but are more representative of the mid- to larger-sized facilities. Below is a comparison of data from the survey and from a recent IPC industry profile report (ref. 2).
| Sales Volume $/yr |
% of Companies IPC Industry Profile Report |
% of Companies PWB Industry Survey Results |
|---|---|---|
| Under $5 million | 75% | 26% |
| $5 to $10 million | 13% | 18% |
| $10 to $20 million | 6% | 24% |
| $20 to $50 million | 4% | 18% |
| Over $50 million | 2% | 11% |
Other measures of facility size show similar variation among survey respondents. The square footage of manufacturing facilities ranged in size from 9,000 ft2 to 600,000 ft2, with a median value of 38,000 ft2 and a mean value of 85,230 ft2. The number of employees ranged from 28 to 1,000 people with median and mean values of 150 and 223 people. In terms of square footage of PWB production, responses ranged from 15,000 to 5,000,000 board ft2 per year, which included single- and double-sided PWBs as well as multi-layer PWBs. Relationships between board production volumes and dollar sales are presented in the IPC industry profile report (ref. 2).
2.3 General Process Information
The survey collected data for numerous process related topics. Some of the general process characterization data are discussed in this section.
Printed wiring board production may be categorized is several ways. Layer count is a common method of categorization because it relates to overall technology level (i.e., higher layer counts require more sophisticated technology). Board price is also related to layer count. The average cost for a single-sided board is $0.58, while the average cost for a multi-layer board is about $22 (ref. 2). Among respondents, the most commonly produced board is the double-sided board (see Exhibit 2-2 and Exhibit 2-3. Ninety percent of the respondents reported producing double-sided boards, while 63% percent of the respondents reported producing somesingle-side boards and 87% reported producing at least some multi-layer panels. Of those shops performing multi-layer manufacturing, the largest percentage of shops (94%) produce 4-6-layer boards. The number of shops producing higher layer counts dropped sharply with increasing layers; only two shops reported manufacturing any boards with more than 20 layers. In general, the production of higher layer boards is performed more by the larger production shops (> 500,000 ft2/yr) than the smaller ones. One major exception is respondent 6710.
| Type of PWB Product (% of board ft2) |
Technology Level (% of board ft2) |
|||||||||
|---|---|---|---|---|---|---|---|---|---|---|
| Respondent ID |
Production (board ft2 per year) |
Rigid | Flex | Combin- ation |
Single Sided |
Double Sided |
4-6 Layers |
8-12 Layers | 14-20 Layers | More than 20 Layers |
| 36930A | nr | 0 | 60 | 40 | 0 | 60 | 20 | 18 | 2 | 0 |
| 955099 | nr | 100 | 0 | 0 | 5 | 40 | 30 | 24 | 1 | 0 |
| 55595 | nr | 100 | 0 | 0 | 5 | 60 | 30 | 5 | 0 | 0 |
| 44486 | nr | 100 | 0 | 0 | 0 | 30 | 60 | 10 | 0 | 0 |
| 955703 | nr | 100 | 0 | 0 | 0 | 10 | 65 | 20 | 5 | 0 |
| 6710 | 15,000 | 100 | 0 | 0 | 0 | 5 | 0 | 15 | 80 | 0 |
| 947745 | 40,000 | 100 | 0 | 0 | 5 | 65 | 28 | 2 | 0 | 0 |
| 44657 | 42,358 | 100 | 0 | 0 | 5 | 50 | 25 | 18 | 2 | 0 |
| 29710 | 57,000 | 100 | 0 | 0 | 0 | 60 | 30 | 10 | 0 | 0 |
| 502100 | 60,000 | 0 | 95 | 5 | 50 | 45 | 0 | 5 | 0 | 0 |
| 32482 | 75,000 | 90 | 10 | 0 | 5 | 70 | 20 | 5 | 0 | 0 |
| 25503 | 90,000 | 5 | 85 | 10 | 70 | 20 | 3 | 2 | 0 | 0 |
| 36930 | 96,000 | 100 | 0 | 0 | 0 | 3 | 70 | 25 | 2 | 0 |
| 965874 | 175,000 | 100 | 0 | 0 | 15 | 85 | 0 | 0 | 0 | 0 |
| 953880 | 180,000 | 100 | 0 | 0 | 5 | 55 | 30 | 10 | 0 | 0 |
| 33089 | 200,000 | 100 | 0 | 0 | 20 | 80 | 0 | 0 | 0 | 0 |
| T3 | 200,000 | 98 | 1 | 1 | 10 | 30 | 50 | 10 | 0 | 0 |
| 3470 | 240,000 | 100 | 0 | 0 | 5 | 83 | 11 | 1 | 0 | 0 |
| 43841 | 250,000 | 100 | 0 | 0 | 10 | 50 | 24 | 15 | 1 | 0 |
| 279 | 250,000 | 100 | 0 | 0 | 75 | 25 | 0 | 0 | 0 | 0 |
| 237900 | 273,000 | 100 | 0 | 0 | 1 | 5 | 65 | 29 | 1 | 0 |
| 273701 | 280,000 | 98 | 2 | 0 | 5 | 70 | 25 | 0 | 0 | 0 |
| 41739 | 300,000 | 100 | 0 | 0 | 32 | 50 | 27 | 1 | 0 | 0 |
| 959951 | 320,000 | 100 | 0 | 0 | 8 | 80 | 12 | 0 | 0 | 0 |
| 42692 | 360,000 | 100 | 0 | 0 | 3 | 62 | 35 | 0 | 0 | 0 |
| 358000 | 500,000 | 100 | 0 | 0 | 0 | 30 | 50 | 15 | 5 | 0 |
| 43694 | 500,000 | 0 | 100 | 0 | 74 | 23 | 3 | 0 | 0 | 0 |
| 37817 | 540,000 | 100 | 0 | 0 | 80 | 20 | 0 | 0 | 0 | 0 |
| 42751 | 540,000 | 100 | 0 | 0 | 0 | 10 | 20 | 50 | 20 | 0 |
| T2 | 600,000 | 100 | 0 | 0 | 0 | 40 | 43 | 12 | 5 | 0 |
| 133000 | 600,000 | 0 | 60 | 40 | 4 | 60 | 5 | 25 | 5 | 1 |
| T1 | 936,000 | 100 | 0 | 0 | 0 | 10 | 28 | 50 | 10 | 1 |
| 740500 | 1,800,000 | 100 | 0 | 0 | 0 | 0 | 80 | 20 | 0 | 0 |
| 946587 | 1,900,000 | 100 | 0 | 0 | 0 | 10 | 65 | 20 | 5 | 0 |
| 3023 | 2,300,000 | 100 | 0 | 0 | 0 | 0 | 70 | 15 | 15 | 0 |
| 31838 | 3,000,000 | 100 | 0 | 0 | 0 | 0 | 30 | 40 | 30 | 0 |
| 462800 | 3,750,000 | 100 | 0 | 0 | 100 | 0 | 0 | 0 | 0 | 0 |
| 107300 | 5,000,000 | 100 | 0 | 0 | 10 | 85 | 5 | 0 | 0 | 0 |
Another method of comparing PWB manufacturing processes is variation of substrate type (Exhibit 2-2 and Exhibit 2-4). The two basic types of substrates are flexible (sometimes referred to as flex) and rigid. Unlike layer count categories where most shops produce at least some single-, double- and multi-layer boards, shops typically manufacture PWBs using rigid or flex substrates. Although the flex and rigid manufacturing processes are similar (base laminates, multi-layer construction, and surface finishing are the major areas of divergence), only one respondent reported manufacturing a significant percentage of both rigid and flex PWBs (respondent ID# 32483, 90% rigid, 10% flex).
Exclusively rigid manufacturers are most common among survey respondents. Seventy-nine percent of respondents are exclusively rigid board manufacturers and 10.5% are exclusively non-rigid manufacturers.
A third category of PWB substrate type is rigid/flex combination. These boards consist of rigid and flex substrates that are bonded together to form three-dimensional PWB structures. They are often referred to as rigid/flex boards. Rigid/flex combinations are manufactured by 13.2% of respondents. Only one predominantly rigid manufacturer reported producing any rigid/flex combinations (ID# T3, 1% of total ft2). All other rigid/flex producers are flex manufacturers.b
In addition to the respondent discussed previously (ID# 32483), three other shops produce both rigid and flex boards, but their production is overwhelmingly either rigid or flex (ID# 25503: 5% rigid, 95% non-rigid; ID# T3: 98% rigid, 2% non-rigid; and ID# 273701: 98% rigid, 2% non-rigid).
Survey recipients were asked to provide current data on base laminate material used in their PWB manufacturing. The responses to this question are presented in Exhibit 2-5. Among base materials used for rigid PWBs (epoxy resin with a woven glass laminate surface) predominate. Ninety-seven percent of respondents reported manufacturing PWBs on FR-4 or multi-functional FR-4 substrates. Among exclusively rigid manufacturers, cyanate ester is used by 8.8%, PTFE (polytetrafluroroethylene) by 14.7%, and polyimide by 29.4% of these shops. CEM material, usually reserved for the lower technology single- and double-sided PWBs, is used by 35.3% of the rigid manufacturers. Among survey respondents, CEM material is used mostly by moderate to high production shops that produced single- or double-sided PWBs. CEM material includes CEM-1 (paper-epoxy resin core with woven glass on the laminate surface) and CEM-3 (epoxy resin with non-woven glass core and woven glass on the laminate surface)
| Base Materials Used
for Rigid PWB Manufacture (% of board ft2) |
|||||||||
|---|---|---|---|---|---|---|---|---|---|
| Respondent ID |
Production (board ft2 per year) |
Percent Rigid |
CEM | FR-4 | Multi- functional |
Cyanate Ester |
PTFE | Poly- imide |
Other Materials |
| 955099 | nr | 100 | 0 | 100 | 0 | 0 | 0 | 0 | 0 |
| 55595 | nr | 100 | 0 | 90 | 10 | 0 | 0 | 0 | 0 |
| 44486 | nr | 100 | 0 | 0 | 100 | 0 | 0 | 0 | 0 |
| 955703 | nr | 100 | 0 | 85 | 15 | 0 | 0 | 0 | 0 |
| 6710 | 15,000 | 100 | 0 | 0 | 100 | 0 | 0 | 0 | 0 |
| 947745 | 40,000 | 100 | 0 | 70 | 0 | 0 | 0 | 30 | 0 |
| 44657 | 42,358 | 100 | 2 | 88 | 5 | 0 | 0 | 5 | 0 |
| 29710 | 57,000 | 100 | 0 | 100 | 0 | 0 | 0 | 0 | 0 |
| 32482 | 75,000 | 90 | 0 | 60 | 30 | 0 | 5 | 5 | 0 |
| 36930 | 96,000 | 100 | 0 | 0 | 96 | 1 | 0 | 3 | 0 |
| 965874 | 175,000 | 100 | 0 | 100 | 0 | 0 | 0 | 0 | 0 |
| 953880 | 180,000 | 100 | 0 | 95 | 4 | 0 | 0 | 1 | 0 |
| 33089 | 200,000 | 100 | 5 | 95 | 0 | 0 | 0 | 0 | 0 |
| T3 | 200,000 | 98 | 5 | 0 | 0 | 0 | 5 | 5 | 101 |
| 3470 | 240,000 | 100 | 1 | 83 | 0 | 0 | 0 | 1 | 152 |
| 43841 | 250,000 | 100 | 2 | 0 | 96 | 0 | 2 | 0 | 0 |
| 279 | 250,000 | 100 | 25 | 75 | 0 | 0 | 0 | 0 | 0 |
| 237900 | 273,000 | 100 | 0 | 98 | 2 | 0 | 0 | 0 | 0 |
| 273701 | 280,000 | 98 | 5 | 50 | 43 | 0 | 0 | 2 | 0 |
| 41739 | 300,000 | 100 | 1 | 80 | 10 | 0 | 9 | 0 | 0 |
| 959951 | 320,000 | 100 | 2 | 98 | 0 | 0 | 0 | 0 | 0 |
| 42692 | 360,000 | 100 | 0 | 100 | 0 | 0 | 0 | 0 | 0 |
| 358000 | 500,000 | 100 | 0 | 70 | 30 | 0 | 0 | 0 | 0 |
| 37817 | 540,000 | 100 | 75 | 25 | 0 | 0 | 0 | 0 | 0 |
| 42751 | 540,000 | 100 | 0 | 90 | 10 | 0 | 0 | 0 | 0 |
| T2 | 600,000 | 100 | 0 | 40 | 60 | 0 | 0 | 0 | 0 |
| T1 | 936,000 | 100 | 0 | 70 | 15 | 1 | 0 | 12 | 13 |
| 740500 | 1,800,000 | 100 | 0 | 100 | 0 | 0 | 0 | 0 | 0 |
| 946587 | 1,900,000 | 100 | 0 | 50 | 40 | 0 | 5 | 5 | 0 |
| 3023 | 2,300,000 | 100 | 0 | 5 | 80 | 5 | 0 | 0 | 101 |
| 31838 | 3,000,000 | 100 | 0 | 20 | 80 | 0 | 0 | 0 | 0 |
| 462800 | 3,750,000 | 100 | 80 | 20 | 0 | 0 | 0 | 0 | 0 |
| 107300 | 5,000,000 | 100 | 15 | 80 | 5 | 0 | 0 | 0 | 0 |
1 GETEK
2 Bendflex
3 BT
nr = no response
Process capabilities in terms of layer counts have already been discussed. Other common categories of process capabilities include minimum via size (the smallest hole that is drilled and plated successfully) and minimum trace width (the smallest feature that can be imaged and etched successfully). Process capability data are presented in Exhibit 2-6. Drill equipment generally is the limiting factor for hole sizes, whereas cleanliness, photoresist type, etching practices and equipment, and other less distinct issues determine trace-width capabilities. Respondents reported minimum via capabilities ranging from 0.002 inches (holes of this size are generally referred to as "micro-vias") to 0.022 inches in diameter. Trace widths as low as 0.002 inches are produced by one respondent. Thirty-eight percent of respondents reported manufacturing trace widths less than 0.005 inches. Traces in the 0.002-0.003 inches range are generally considered to be the smallest practical trace width achievable with common photo-resists and etchants.
| PWB Type (% board ft2) |
Process Capabilities | |||||||||
|---|---|---|---|---|---|---|---|---|---|---|
| Respondent ID |
Production (board ft2 per year) |
Rigid | Non- Rigid | Typical Via (mils) |
Min. Via (mils) |
Typical Trace (mils) |
Min. Trace (mils) |
Max. Layers1 |
Mil-P- 55110 |
ISO- 90002 |
| 36930A | nr | 0 | 100 | 20 | 8 | 8 | 4 | 18 | YES | YES |
| 955099 | nr | 100 | 0 | 7 | 5 | 8 | 5 | 16 | NO | YES |
| 55595 | nr | 100 | 0 | 22 | 13 | 10 | 6 | 8 | NO | YES |
| 44486 | nr | 100 | 0 | 0 | 8 | 6 | 3 | 12 | NO | YES |
| 955703 | nr | 100 | 0 | 14 | 14 | 5 | 4 | 0 | NO | YES |
| 6710 | 15,000 | 100 | nr | nr | nr | nr | nr | nr | YES | NO |
| 947745 | 40,000 | 100 | 0 | 20 | 12 | 12 | 7 | 10 | NO | YES |
| 44657 | 42,358 | 100 | 0 | 18 | 8 | 8 | 5 | 16 | YES | YES |
| 29710 | 57,000 | 100 | 0 | 25 | 20 | 8 | 8 | 8 | NO | YES |
| 502100 | 60,000 | 0 | 100 | 20 | 16 | 15 | 8 | 14 | YES | YES |
| 32482 | 75,000 | 90 | 10 | 20 | 12 | 8 | 3 | 15 | YES | YES |
| 25503 | 90,000 | 5 | 95 | 18 | 2 | 8 | 2 | 12 | NO | NO |
| 36930 | 96,000 | 100 | 0 | 16 | 14 | 8 | 5 | 18 | YES | YES |
| 965874 | 175,000 | 100 | 0 | 25 | 15 | 10 | 8 | 2 | NO | YES |
| 953880 | 180,000 | 100 | 0 | 18 | 18 | 7 | 7 | 12 | NO | YES |
| 33089 | 200,000 | 100 | 0 | 25 | 22 | 20 | 10 | 2 | NO | NO |
| T3 | 200,000 | 98 | 2 | 18 | 6 | 7 | 3 | 12 | NO | YES |
| 3470 | 240,000 | 100 | 0 | 18 | 14 | 10 | 7 | 8 | YES | YES |
| 43841 | 250,000 | 100 | 0 | 8 | 8 | 12 | 4 | 16 | YES | YES |
| 279 | 250,000 | 100 | 0 | 30 | 18 | 12 | 8 | 2 | NO | NO |
| 237900 | 273,000 | 100 | 0 | 25 | 20 | 6 | 3 | 18 | YES | YES |
| 273701 | 280,000 | 98 | 2 | 20 | 10 | 10 | 6 | 6 | NO | YES |
| 41739 | 300,000 | 100 | 0 | 28 | 13 | 10 | 5 | 10 | YES | NO |
| 959951 | 320,000 | 100 | 0 | 18 | 10 | 8 | 5 | 8 | NO | NO |
| 42692 | 360,000 | 100 | 0 | 22 | 13 | 10 | 6 | 6 | NO | YES |
| 358000 | 500,000 | 100 | 0 | 15 | 12 | 7 | 5 | 14 | YES | YES |
| 43694 | 500,000 | 0 | 100 | 18 | 10 | 8 | 5 | 14 | NO | YES |
| 37817 | 540,000 | 100 | 0 | 20 | 16 | 10 | 10 | 2 | NO | NO |
| 42751 | 540,000 | 100 | 0 | 18 | 10 | 5 | 3 | 24 | NO | YES |
| T2 | 600,000 | 100 | 0 | 18 | 8 | 8 | 5 | 16 | NO | YES |
| 133000 | 600,000 | 0 | 100 | 18 | 13 | 7 | 7 | 24 | YES | YES |
| T1 | 936,000 | 100 | 0 | 18 | 10 | 8 | 3 | 24 | NO | NO |
| 740500 | 1,800,000 | 100 | 0 | 14 | 10 | 5 | 3 | 18 | NO | YES |
| 946587 | 1,900,000 | 100 | 0 | 4 | 2 | 5 | 3 | 20 | NO | YES |
| 3023 | 2,300,000 | 100 | 0 | 20 | 12 | 8 | 4 | 27 | YES | YES |
| 31838 | 3,000,000 | 100 | 0 | 14 | 8 | 5 | 4 | 24 | NO | YES |
| 462800 | 3,750,000 | 100 | 0 | 34 | 18 | 25 | 8 | 3 | NO | YES |
| 107300 | 5,000,000 | 100 | 0 | 25 | 18 | 8 | 5 | 4 | NO | YES |
2 A "YES" response indicates only that the company has at least begun to pursue ISO-9000 certification.
nr = no response
Exhibit 2-6. Process Capabilities of Respondents
Other data displayed in Exhibit 2-6 relate to manufacturing process certifications. Thirty-five percent of respondents reported that they are MIL-P-55110 certified. MIL-P-55110 is the military specification covering PWB manufacturing. Seventy-seven percent of the respondents indicated that they have achieved or initiated the process of achieving ISO-9000 certification. ISO-9000 is an internationally recognized quality standard. Its applicability is not limited to the PWB industry.
