With contemporary electronic products, the circuitry often has to compete for the limited space within the housing. When conventionally stacked, PCBs can no longer accommodate all of the necessary components, so three-dimensional circuit carriers become the choice. But, the ever-shorter life cycles of many devices pose additional challenges: injection molding is too expensive to manufacture prototypes. For this reason, Beta LAYOUT GmbH, a leading manufacturer of printed circuit boards and 3D-MID (mechatronic integrated devices) prototypes, chose to use additive manufacturing technology from EOS.
There is no technology better suited to the demands of multi-layer architecture than additive manufacturing because it builds up a component, layer by layer.
Through additive manufacturing, custom-made circuit carriers can be used for the prototypes of new electronic devices. The plastic components can be produced quickly and at an attractive price.
The process simultaneously offers precision and quality, allowing the basic body to be manufactured as if it were already a close-to-series product.
The EOS technology is flexible; the machine can process various materials, including, for example, PA 3200 GF, which is filled with glass beads, or the aluminum-filled polyamide Alumide. High-performance polymers such as PEEK and various metals are also available. The crucial point is that the materials withstand high temperatures, a limitation of the injection-molding process in series production.
For Beta LAYOUT, the innovation takes place after the printing process itself; once the PCB prototypes have been made, the models are coated with a special finish that is furnished with an additive. The subsequent ‘laser direct structuring’ (LDS) generates layouts, which can be turned into conductor tracks by activating the finish.
In the LDS process, the laser triggers a physical-chemical reaction that creates metallic spores while simultaneously roughening the surface.
After LDS, the models are placed in a copper bath free of electric current. There, copper particles are deposited on the previously activated areas, creating conductor tracks. After copper coating, the conductor tracks can undergo further copper plating through galvanization, or be directly furnished with a surface finish.
After this step, Beta LAYOUT adds the individual components to the unit in the company’s internal assembly department. The finished pieces serve as initial prototypes and models, allowing function testing and a check of design layouts.
“We offer manufacturing of 3D-MID as prototypes for diverse companies,” explains Manuel Martin, Product Manager 3D-MID at Beta LAYOUT GmbH. “Working with EOS’ FORMIGA P 110, we can deliver high-quality products to our customers fast. What’s particularly practical in all this is that we can deal with orders of 3D models through websites and online shops. Additive manufacturing has enabled us to successfully expand our business model.”
Beta LAYOUT was able to develop individual, optimized solutions that were lower in costs, resistant to high temperature, or other specific customer requirements.
“Thanks to its many advantages, additive manufacturing technology offers high added value for a range of market participants. Research and development profits through our services, which, in turn, has a positive impact on our business model. This enables us to offer the benefits of advanced technology to a large number of users.”
Beta LAYOUT GmbH
www.beta-layout.com
EOS
www.eos.info
