In a recent application Nautilus Systems, Inc. (NSI) was contacted by a global manufacturer of high-tech products regarding an application that required high accuracy placement of Kapton Tape to protect sensitive devices during a manufacturing process.  The customer required a placement accuracy of +/- 200 microns (+/- 0.2mm) but also required a statistically reliable process.  Statistical reliability as defined using Cpk values requires that the process perform at a much higher level of accuracy during studies than what is actually required by a print or specification.  The reason for this is that statistical study has proven that a process must normally operate in a tight range to allow for any inconsistencies that will be seen over time.  For example, during a run in a typical 8-hour shift the process may experience some variability.  If during that 8 hours the process utilizes the entire allowable range, statistical theory would expect that the same process will definitely produce ‘out of spec’ components in a longer study, say a 30 day evaluation.  By proving that a process operates in a tight range the manufacturer can have confidence that minor issues or inconsistencies will not cause the process to operate outside of specification.

NSI cooperated closely with the customer to evaluate the ability of our PL100EPi system to provide a statistically reliable process.  The Kapton Tape component was approximately 75mm x 75mm in size with the center removed thus forming a ‘frame-shaped’ component with an ‘ID’ of approximately 60 x 60mm.  NSI developed a custom locating Nest that incorporated spring loaded features to consistently place the substrate against two datum walls and provided a CCT (Custom Component Tooling) package for the PL100EPi to reliably peel and place the Kapton Tape.

Over the course of several weeks the system was developed, tested, and a buyoff run was performed with the customer present.  The system was approved and shipped to the customer site.  Several weeks later the customer provided data from a study that they had performed independently over a 500 pc run.  The study results proved that the system was highly reliable, with a Cpk value in excess of 2.5.  The total measured placement range was +/- 70 microns (+/- 0.7mm) and deeper analysis revealed that the process of die-cutting of the Kapton Tape was leaving uneven edges (as observed under high magnification) on the Tape which actually varied by +/- 40 microns (+/- 0.4mm).  Thus, the customer concluded that the NSI PL100EPi placement accuracy was actually as good as +/- 30 microns (+/- 0.03mm).

NSI strives to provide the most reliable and repeatable placement systems in the world.  Our PL100EPi, with it’s closed-loop monitoring of Tape feed is a uniquely capable system for challenging applications.  While we are quite proud of the performance of the system in this case we must be clear in stating that each die-cut adhesive component is unique and we do not achieve accuracies of this magnitude in all applications but we have proven in numerous applications using a wide variety of materials that our systems are highly reliable and repeatable.  Please contact us for your adhesive component placement needs.  We will evaluate your application and provide feedback regarding our capabilities including assistance with developing the die-cut tapes for best performance in our systems.

Pressure Sensitive Adhesives (PSA) are used in assembly processes of all types.  A wide variety of manufacturers of PSAs provide products to the market.  These PSA products are engineered and developed with specific characteristics to meet virtually any requirements.  An application may require a certain adhesive bond strength between two distinct substrates or may require a specific thickness.  The adhesive may include a protective, insulating, or conductive film laminated to the adhesive to be used for assembly.  There are adhesive transfer and double coated tapes.  There are tapes specifically configured for certain industries such as aerospace, automotive, medical, packaging, food, appliance, construction, and more.  These PSA components are delivered in the form of die-cut tape and can be as simple as labels or as complex as a multi-layer laminate of complex shape that provides functions of gasketing, shielding, and insulating all in a single component.

Nautilus Systems, Inc. (NSI) has a specialized portfolio of equipment solutions for accurately feeding and applying virtually any type of die-cut adhesive component.  The die-cut process is typically provided by a Converter.  A Converter works closely with the End-User, the PSA supplier, and NSI to configure the parts that they will provide to meet the application requirements both from a product perspective and from an assembly perspective.  NSI personnel are able to assist the Converter by providing specifications about the die-cut component layout that will assist in improving the ability to accurately dispense and place those components.

NSI Applicator systems including the PL100i, PL100r, PL165i, and PL165r are currently in use for the precise and reliable assembly of die-cut adhesive components in virtually every industry.  In Medical Device assembly our systems are being used to: apply conductive foils to surgical instruments; applying multiple layers of adhesive materials around electronic circuitry for diagnostics; apply barcode labels in precise positions on test tube units; and more.  In the Automotive industry our Applicators are in use in assembly of: Airbag components; Tire Pressure Monitoring System hardware; and more.  In Semiconductor and Electronic industries our systems are being used to apply Polyimide Tape Masks, Mask Labels using Thermal Adhesives, and more.  In Packaging applications are systems are used to apply Labels, Hang Tabs, and more.

As can be ascertained from the details above, pressure sensitive adhesive component assembly is a wide ranging and far reaching application environnment.  At NSI we have the expertise to assist you with selecting materials, prototyping, developing specifications for die-cut components, developing assembly processes, and implementing equipment using our standardized solutions to provide the most accurate, precise, and reliable assembly process avaialable.  At NSI one of the services we provide is DFMA (Design for Manufacturability and Assembly).  Drawing on a long history in this specialized field allows us to provide resources instantly for this evaluation purpose that many of our customers do not have or do not have the time to develop.

Please call NSI to discuss your application so that we can bring our core competencies to bear in assisting you on the road to success.