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Drilling The point at which the drilling process occurs is determined by the ML-PWB sequence chosen 274111 Standard Drilling of Innerlayers Standard buried via innerlayers are drilled and plated prior to lamination using the same procedures as a finished ML-PWB Buried via innerlayers are typically thin, and it is easy to drill very small holes Whereas an 8 mil hole is difficult to drill and plate in a 62 mil thick ML-PWB, it is relatively easy in a 5 or 10 mil thick innerlayer Some manufacturers report success with holes as small as 4 mil However, very small bits are expensive and easy to break Special handling is required to load the bits and the drill machine must be vibration-free with very low run-out For most ML-PWB shops, 8 mil is a practical lower limit for mechanically drilled buried and blind vias At 8 mil.

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it is generally possible to drill thin layers in stacks up to 100 mil thick, greatly increasing drill productivity However, a 10 mil bit is less costly than an 8 mil bit, so cost-sensitive products should try to design around a 10 mil bit lower limit for buried vias LFAC laminates with fillers can be tougher and more brittle than regular FR-4s requiring different drilling parameters As an example, the standard FR-4 might be drilled at up to 450 surface feet minute (SFM) with a chip load up to 20 mil/rev and a maximum hit count of 1,500 holes; the LFAC epoxy-fiberglass-comparable laminate might be drilled at up to 350 SFM with a chip load up to 15 mil/rev and a maximum hit count of 1,000 holes Consult your laminate manufacturer s guidelines or applications engineer The major challenge in buried via processing is handling.

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Care must be taken in mechanical operations such as deburring to avoid mechanical damage or distortion Often a frame is used to stiffen the layer during plating Blind vias may be fabricated like buried vias and mechanically drilled in a top (or bottom) sub-lamination section prior to full board lamination, or controlled-depth drilling may be used after lamination..

Controlled-depth drilling has the advantage that standard innerlayer processing is used, including foil stacking. Controlled-depth drilling has several limitations:

Blind holes cannot be stack-drilled, severely limiting drill productivity. It is difficult to plate a blind hole whose depth exceeds its diameter; this necessitates limiting the maximum hole depth or increasing the drill diameter such that a maximum aspect ratio of 1:1 is preserved. Drill depth tolerances make it easy to under- or overdrill a blind hole, producing a quality or reliability risk.

Now we calculate the curvature two forms using (5.27). We explicitly calculate r:

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All of these limitations are avoided when the blind vias are drilled through a two-sided board used for the outerlayer and next innerlayer in a stack-up These holes are drilled prior to lamination just as a thin two-sided plated through board In this case, the process sequence for a blind via layer is identical to the sequence for a buried via layer Such layers can be stackdrilled There is no aspect ratio limitation and the need for controlled-depth drilling is completely eliminated To be able to drill blind vias prior to lamination, a clad outer stack-up is required One side of the outer component layer is patterned prior to lamination, while the other is patterned after laminationThis means that when the blind via is metallized, the unpatterned side is blanket-metallized This is true for either pattern plate or panel plate.

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This outside layer is metallized again when the holes in the finished ML-PWB are metallized The result can be very thick plating on the exterior of a blind via board To minimize this problem, the fabricator should plate the blind via innerlayer with the minimum possible current density on the blanket-metallized side 274112 Drilling Related to Laminated Subcores The drilling process for laminated subcores usually follows the rules for finished board drilling and is design-dependent When designs follow this methodology, they typically push the limits of plating aspect ratio Density constraint typically drives this requirement due to routing availability In this case, additional density can be gained through the use of laser blind vias 274113 Laser Drilling Laser-drilled blind vias can be placed on either or both sides of the ML-PWB, and they have inherently accurate depth control.

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