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ESI unveils innovative products for LED manufacturing

The firm is introducing advanced systems for LED micromachining, wafer scribing and testing, which are all designed to deliver the lowest cost of ownership.

Supplier of laser-based manufacturing solutions for the microtechnology industry, Electro Scientific Industries (ESI) is showcasing its expanded suite of LED manufacturing systems and applications at Semicon West 2011 this week.

The first of the new systems is the Model 5390 micromachining system for advanced LED packaging. This tool is uniquely designed for creation of electrical interconnections on LED packages and is optimised for industry-leading via placement accuracy and high yields.

"Our customers are demanding new, innovative manufacturing processes that enable them to enhance light output and product reliability on smaller and smaller LED packages," said Martin Orrick, senior director in ESI's Interconnect and Micromachining Group. "Our Model 5390 enables the industry's fastest and highest via placement accuracy."

Featuring a high-speed compound beam positioner coupled with a high-power CO2laser, the Model 5390 provides user-definable variable pulse width and pulse repetition frequencies of up to 300 kHz for wide range of applications. The system can produce more than 100 vias per second in typical single layer dielectric materials. The company shipped the first unit to a leading LED manufacturer in the last quarter.


The firm is also unveiling its most advanced LED wafer scribing system, the AccuScribe 2600. ESI’s AccuScribe 2600 is built on patented, industry-leading technology enabling customers to extract the maximum light output from LED’s. ESI developed the AccuScribe 2600 based on customer requirements for high brightness LED (HB-LED) manufacturing, including Patterned Sapphire Substrate (PSS), Distributed Bragg Reflector (DBR), Metal Mirror (MM) and other advanced light extraction technologies.

“ESI pioneered the laser scribing of LED wafers with our patented technology for LED sapphire substrates,” said Jonathan Sabol, general manager of ESI’s LED µEngineering Division. “Industry wide expansion of high brightness LEDs is driving rapid changes in LED architecture and manufacturing processes to continuously increase lumens/watt. The AccuScribe 2600 is specifically designed to match our customers’ most demanding technology roadmaps while achieving industry best yield, performance and cost.”

Multiple customers have recently confirmed that the AccuScribe 2600 delivers the industry’s highest brightness scribing for a wide range of HB-LED technologies including PSS, DBR and MM.

Increased light output results in increased revenue and profitability for LED manufacturers. This, coupled with achieving the highest yield, lowest cost, least environmental impact, and complete elimination of the employee work hazards related to chemical etching, will allow ESI Accuscribe 2600 customers to lead in the most profitable segment of the HB- LED market.

The firm is also introducing the high-speed Model 3800 production-scale LED Tester. The 3800 features an innovative architecture that utilises a patented, dual-track, bulk-to-bin handler that has demonstrated in excess of 100 percent throughput improvement and yields in excess of 99.9%. It processes two LEDs simultaneously, while achieving productivity rates up to 48,000 LEDs/hr (800/min). The system has multiple test stations to maintain the highest possible throughput and each system can be configured to test multiple LED types and testing requirements.

What’s more, the rotary loader is gentle on LED packages to drastically reduce chip damage and indexed carriers maintain LEDs in a "nest" to eliminate dropped and scrapped devices. The simple, parallel binning process does not require actuated gates/switches and virtually eliminates mis-binning, and does not limit throughput.

"Consumer adoption of high brightness LED technology depends largely on our customers' ability to drive down their production costs and improve LED light efficiency through advances in manufacturing technology," said Vernon Cooke, product manager in ESI's Components Group. ESI says the Model 3800 is the most advanced LED tester on the market.

ESI has a long, proven history as one of the market leaders in the delivery of automated systems designed for mass-production testing and inspection of small, electronic components, such as multi-layer ceramic capacitors (MLCCs). The company has applied its core technologies of component handling, testing and binning to significantly reduce the cost of ownership for LED manufacturing.

ESI expects to ship its first system to a leading LED manufacturer this quarter.

The firm is showcasing its solutions for LEDs at SEMICON West at booth #5871 in the North Hall at San Francisco's Moscone Convention.
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