Orbotech | Be Sure

With Laser Direct Imaging being widely recognized as an enabling production technology now for mass production in addition to advanced PCB applications and QTA, understanding the cost of utilizing this tool is a critical factor in its justification.

One area to look at in terms of real cost-savings is the use of resists. A common misconception is that using conventional resists for LDI is cheaper than using LDI resist. While this may be true about the upfront purchase price of conventional resist itself, the increase in LDI throughput that results from the use of LDI resist significantly lowers imaging costs which shows it to be actually less expensive overall.

So, is it really possible to achieve even greater LDI throughput and lower the cost of ownership on the same LDI system just by switching to LDI resist from conventional resist? A closer look reveals the advantages: double throughput, lower cost per panel, less yellow room space requirements, all while still achieving the highest image quality.

With the performance of today's fast LDI resists, it is possible to achieve double the imaging throughput, compared to conventional resists, while also reducing the number of exposure systems needed in the imaging operation.

For example: A state-of-the-art LDI system using LDI resist can image a 24" x 18" panel at a rate of up to 240 panels/hour. While using conventional resist at 50mJ/cm², on other LDI system, can achieve a throughput rate of only about 120 to 140 panels/hour.

Even though the cost of LDI resist is more expensive than conventional resist, the dramatic increase in throughput possible with LDI resist enables a major reduction in the imaging cost per panel.Because of the greater LDI capacity, the fixed costs associated with imaging can be spread over a larger number of panels. This includes equipment depreciation, service, labor, etc.

Another important contributor to lower panel cost when using LDI resist is economies of scale.The more LDI resist that is purchased from the resist supplier, the lower the price. For instance, if typically there is a premium of up to 100% charged for LDI resist in small quantities, compared to conventional resist, it is reasonable that the premium could be reduced to as little as 30% for higher volume purchases.

With an LDI system able to achieve double the capacity using LDI resist, only 50% of machines are needed for the imaging process. This significantly reduces the space required for the yellow room and its related costs: real estate, equipment, utilities, labor andmaintenance.

When switching to LDI resist, there is no trade-off in image quality. Imaging on LDI resist achieves the same quality results, in terms of accuracy and yield, as when printing with conventional resist--regardless of design complexity.

With the ever-present challenge to make the imaging process better, faster and cheaper, LDI users and suppliers are looking at new ways to achieve more with existing or even less equipment. Utilizing the most advanced LDI technology, together with LDI resist, can result in a very effective imaging solution that not only significantly improves yields and reduces operational costs, but greatly increases digital imaging throughput while maintaining high image quality.