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Productivity of the laser is very high When employing laser blind drilling, it is necessary to use thin insulating dielectrics to produce a thin stack height to the sublayer Depending on the type of laser employed, it is sometimes necessary to image fiducial targets the next layer down for alignment This is the case when employing an UV or Nd:YAG laser, which can penetrate copper Other laserdrilling alignment targets are required when employing a carbon dioxide (CO2) laser, which will penetrate only the dielectric Very high drill rates can be achieved on a scanning CO2 laser Here a mask pattern is etched in the copper to allow exposure of the laser beam to the dielectric The laser removes the dielectric, stopping at the copper pad below Multiple via stacks can be accomplished with this method by repeating the mask opening at different layer depths.

Aspect ratio should always be kept in mind Most success has been reported when the mask diameter is kept greater than 0003 in For best accuracy, a minimum of three etched targets is required and should be referenced to the CNC drill data..

The lamination process is an essential step in the fabrication of an ML-PWB. The process is also one of the longest cycle time operations. Therefore, when the process method calls for repeat cycles, or what is called sequential laminations, it can be a significant cost driver. (Note: Sequential lamination is often paired with distinct, separate drill and plate processes for the

subcore that further ratchets up pricing, as they are also time-intensive operations.) The lamination process involves two distinct yet linked operations: lay-up and laminating. 27.5.1 Lay-Up and Materials Lay-up occurs in a clean and controlled room environment. The level of environmental control depends on the circuit feature technology being fabricated. The lay-up process for standard multilayer processing is relatively forgiving. However, working with material that is hygroscopic will require additional measures. The innerlayer details require a bake cycle (typically 120 C for 1 hour minimum) to remove moisture. A reduced bake cycle duration is indicated when certain oxide reduction chemistries are employed. Once layers are readied for lay-up, they should be processed as soon as possible. Should extended hold times become necessary, storage in a nitrogen-purged dry box is recommended. The lay-up operation is often referred to as building up a book. The operation follows a guide, often referred to as a stack-up sheet. The guide sheet, which depicts the engineering design of the ML-PWB, is highly recommended to minimize error. The written and illustrated guide to the book build-up process is made a part of the job planning/traveler. Due to the complexity of some products, the operator follows this guide in a recipe-type manner to perform the systematic construction. The lay-up may consist of some four or more PWB material components or other subassemblies. The lay-up operation produces a large assembly when complete that consists of the tooling plates, consumable press materials, and the ML-PWB detail. Refer to Fig. 27.34 and 27.35 for illustrations of the following.

27511 Tooling Plates The outermost item in the stack is termed a caul plate or carrier plate These are thick, oversized metal plates, generally made of 3/8 in (9525 mm/0375 in) thick steel The 4130 alloy of steel is often chosen due to its precision machining capability for placement of the holing holes Sometimes a hardened aluminum alloy is chosen, but is not highly recommended due to its high in-plane expansion The purpose of the caul plate is to provide a stable base to transport the ML-PWB stack 27512 Separator Plates The multilayer boards in the stack are isolated from each other by metal separator plates The separator plates provide a mold surface for the laminated MLPWB It is extremely important that the separator plates be clean and free of debris Both aluminum and steel separator plates are used.

Separator plates should be cleaned regularly The surface finish of the plates becomes very critical when laminating against microfoils that will be printed with fine lines The most common type of steel is one of the 400 series stainless steels that have a very durable surface Hardened 300 series steels are also occasionally used Separator plate thicknesses range from as thin as 0015 in to as thick as 0062 in The thicker plates are more rigid and resist the tendency of internal layer features to print through from one ML-PWB to anotherThin aluminum plates have the advantage of being disposable, eliminating the need for cleaning 27513 Consumable Press Materials The purposes of consumable press materials placed between the tooling plate and the top layer are to ensure that pressure is applied uniformly and to provide thermal lagging to correct heat rise.

The purposes of consumable release sheets placed in contact with the foils are to protect the outerlayer foils, keeping them resin-free, and to allow easy separation of the foil from the separator sheet..