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The development process must be set up to ensure that the smallest holes are free of undeveloped solder mask This is very different from photoresist because the breakpoint will often be 10 to 15 percent of the development chamber instead of nearly 50 percent with photoresist Key process variables for the development process are the time in the developer and rinse sections; solution temperature, pressure, and nozzle type; flow rate; and configuration It is very important to have an inspection step immediately after development to check for registration, mask in holes, feature resolution, dam retention, lifting, and so on Once the panels have been cured it is significantly more difficult to strip and rework the solder mask, and the rework process is more likely to cause the panels to be scrapped 33522 Dry-Film Solder Mask (DFSM) Application.

The process for DFSM differs from LPI solder mask only in the application step Surface preparation, exposure development, and cure are the same as for LPI solder masks 335221 Application with Vacuum Lamination DFSMs typically have no solvent in them to enable them to conform to circuits without entrapping significant amounts of air along or between circuit tracesTo apply these films to circuit topography, a laminator must be able to laminate panels in a vacuum chamber The predominant type of vacuum laminator has heated upper and lower platens The panel or boards to be coated will have DFSM gently applied (without any pressure) to one or both sides and are placed into the vacuum chamber formed between the upper and lower platens The platens are closed together and a seal is formed Vacuum is drawn in the chamber.

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When a specified time has been reached (determined by the board type and thermal mass, DFSM type and thickness, and board/panel plated circuit height), the flexible diaphragm on the upper platen (which had been held tightly against the upper platen surface by vacuum) is released to slap down onto the panel surface The heat will have made the DFSM plastic so that it will conform to the circuits, and the vacuum prevents poor lamination along circuits The lamination is completed when the platens separate and atmospheric pressure forces the DFSM into all voids 335222 Roll Lamination Lamination of DFSM with a standard hot roll laminator is unacceptable for all except the least demanding applications It is impossible to laminate a flat film of solder mask to PCB topography without trapping air along circuits.

There are vacuum hot roll laminators that will work satisfactorily, but these are not widely available 33523 Non-Imageable 335231 UV and Thermally Curable Solder Masks Because these products are not photoimageable, they must be applied with patterned screen printing in the exact pattern that is needed on the finished PCB After their application, they are cured by the appropriate cure recipe as dictated by the supplier There is no opportunity to develop off solder mask from areas where it is unwanted, so registration of the screen to the panel is very important 335232 Ink Jet Application This technique utilizes digital data and ink jet technology to coat solder mask only in areas where it is wanted This eliminates the photoimaging steps and should reduce or eliminate registration problems.

As of the writing of this book, no such machines are being used in production for solder mask application..

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