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Stencils as Problem Solvers
December 31, 1969 |Estimated reading time: 2 minutes
COEUR d'ALENE, Idaho — Times have changed since Mike Ray began working at his father's firm, Lorry Photography, in the '60s. The firm pioneered photomechanical techniques and tools for producing printed circuit boards (PCBs) for pioneers like William Shockley, Ph.D. The firm later changed its name to Integrated Ideas and Technologies Inc. (IIT), continuing the practice of using innovative manufacturing ideas. In the '80s, IIT reportedly was one of the only stencil manufacturers that was a true single source for stencils — providing everything from consultation and design through complete stencil fabrication.
"While other stencil companies have struggled, IIT has continued to expand its business."
Today, IIT uses YAG lasers with proprietary optical tuning technology to create an astonishing spot size of less than 1 mil. "The optical tuning cavity allows us to cut full-hard stainless steel with extremely smooth, precise walls, which ensures optimal paste release and eliminates the 'postage stamp effect' common with some off-the-shelf lasers," Ray explains.
As components become finer in pitch, highly accurate stencils designed for ultra-precise paste placement become increasingly important. Each new iteration or board revision requires a specific stencil. Paste volume and print location are critical when creating a custom stencil.
When other stencil companies have struggled, IIT has continued to expand its business. One reason is its ability to fine-tune the laser. By using an in-house-designed tuning cavity, precise cuts can be made. "We work closely with our customers, customizing stencils as needed," says Ray. "A stencil works best if it takes into consideration the reaction of the paste upon placement of the component. Rework doesn't have to be a part of everyday business. A carefully designed, precisely cut stencil at the beginning of the line makes all the difference. Furthermore, a stencil can be adjusted to work perfectly, even with complex components.
"Users might not understand that the stencil manufacturer can fix problems. Often, the stencil can be used to adjust paste positioning — from the heel to the toe, for example — to accommodate differences between board design and actual lead locations. Many times, we are able to overcome everyday problems through stencil modifications, which significantly reduces or eliminates costly rework."
In addition to stencil production, Ray and IIT have introduced several industry firsts, including ProFrame II, an aluminum and stainless steel frame with interchangeable Pro Plate II stencils. Some of IIT's most recent inventions include Pro Plate IV, the latest in the line of plate-only systems; Desk Top stencils, a stencil prototyping system including board alignment, print base and squeegee; T-CAT, a self-registering tabletop printing system for application of thermal compounds; Permafid, a permanent fiducial that is laser-created on each stencil; one-size-fits-all PalletMaster; and rework stencils.
"Scheduled for introduction in 2004, IIT's latest stencil production system will forever change the stencil manufacturing industry," Ray says.
— Gail Flower