In the fast-paced world of modern electronics manufacturing, where new products are churned out at an unprecedented pace, the challenges faced by process engineers have evolved significantly. The once leisurely process of verifying each aperture has been replaced by a need for speed, efficiency, and accuracy. Welcome to the era where “smart” stencil verification methods are the keystones of success.
During our engineers’ visits to various manufacturing sites, a common thread emerged: most manufacturers now outsource the design of their stencils to specialized suppliers. On the surface, this might seem like a pragmatic solution. However, lurking beneath the surface are recurring concerns voiced by process engineers across the industry:
“When confronted with intricate PCBA layouts, the painstaking process of manually verifying stencil Gerber files becomes a daunting task. It’s time-consuming and demands the best of our attention. This challenge amplifies when dealing with boards featuring over 10,000 pads or more than 5,000 components.”
“The manual approach to verification, or even reliance on Excel spreadsheets, is no longer viable in today’s fast-paced manufacturing landscape.”
“I wish to be able to rectify violations on the spot, rather than waiting for suppliers to address them, often hours later.”
In response to these challenges, a new software (Vayo Stencil Designer Expert) for verifying aperture-related issues and facilitating swift corrections has emerged. It enables batch importing, creation, and matching of enterprise aperture libraries, provides aperture design templates, facilitates automated stencil design, and conducts comprehensive reviews and verification of the designed apertures, ultimately aiding enterprises in achieving digital transformation.
The following paragraph is to share the software’s interface for verifying aperture issues and easy correction.
Following is the formula for the area ratio & aspect ratio we got from IPC 7525:
Aspect Ratio = Width of Aperture / Thickness of Stencil Foil = W / T
Area Ratio = Area of Pad / Area of Aperture Walls = L x W / 2 x (L + W) x T
Now we need a solution to run automatic analysis, instead of a human approach.
In Vayo Stencil Designer, PCBA stencil validation takes only one click. Then all results are shown for review.
From the result list, you can jump to each location of “Area ratio/Aspect ratio” violations.
If you choose to handle it by yourself, the solution allows aperture edit with the easiest approach.
The validation also reports if the aperture to aperture has been too close:
You may set a safety distance per wish, then make a tuning by the software automatically!
You can edit the pad a little, to fit the safety clearance without violating the area ratio/aspect ratio. You can try to edit all results, to clear them at once, then export tuned Gerber of stencil for your suppliers.
Vayo’s Stencil Designer, the automated stencil verification tool can analyze the entire stencil layout, flagging discrepancies and violations with lightning speed. This enables engineers to swiftly identify and address issues, ensuring that stencils are optimized for precision solder paste deposition. The result? Reduced rework, enhanced SMT quality, and a much-needed boost in manufacturing efficiency.
Since 2005, Vayo Technology has been developing in-house software for PCBA engineers. While it’s challenging to showcase all the remarkable functions in a short paragraph, it’s truly worth your experience. Experience the software through the link below and transform repetitive tasks into smarter processes in your daily workflow!