Chose the Best Plastic Parts for Semiconductor ...

If you’re evaluating which plastic parts to use in semiconductor manufacturing, it’s crucial to select materials that align with the industry's stringent standards for precision and durability under extreme conditions. This article delves into the importance of plastic parts in semiconductor manufacturing, focusing specifically on the performance and reliability of materials like PEEK and PPS. We’ll walk you through how to choose the most appropriate plastics to ensure that your semiconductor components meet the required standards of quality and consistency.

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Key Takeaways

• Plastic parts are vital in semiconductor manufacturing due to their high precision, chemical resistance, and ability to withstand electrical shocks. Materials like PEEK, PAEK, PEI, and PPS are commonly used for their superior chemical, thermal, and mechanical properties.
• Maintaining high quality and consistency in semiconductor manufacturing involves adhering to Copy Exact standards and using Coordinate Measuring Machines to ensure parts meet stringent dimensional and compositional specifications.
• Custom solutions in semiconductor manufacturing, including automated systems and collaborations with expert partners like Atlas Fibre, are essential for advancing technology, enhancing efficiency, and meeting specific performance needs.

Understanding the Role of Plastic Parts in Semiconductor Manufacturing

Grasping the significance of plastics in semiconductor manufacturing allows for a deeper appreciation of these essential components. Plastic parts meet stringent standards of precision and purity, aiding in the production of semiconductor components like electrical insulators and integrated circuits. They are used in both wet and dry processes, ensuring consistent product manufacturing specifications and high quality.

High-performance characteristics and chemical resistance make plastic ideally suited for producing components like flexible connectors, laminates, and shielding films in semiconductor manufacturing. These attributes directly impact the overall performance of semiconductor products. Additionally, the precision of plastic parts is paramount in maintaining the exacting standards necessary in semiconductor production, ensuring both quality and performance.

Material Properties and Resistance

Evaluating material properties and resistance is essential when selecting plastics for semiconductor applications. The right materials ensure the prevention of harmful contamination.

The resistance of plastics in semiconductor applications is crucial. For instance, polycarbonate resists electrical shock and mitigates static electricity, which is essential in semiconductor device production.

Plastics used in semiconductors also show exceptional chemical resistance, making them suitable for processes involving corrosive chemicals, such as wet benches in semiconductor manufacturing.

Precision and Form

The reliability and performance of plastic parts in semiconductor manufacturing heavily depend on precision and form. Even minor deviations can affect dimensional stability and quality, which impacts the functionality and lifespan of the components.

Using plastic machining techniques, especially automated CNC processes, results in high-precision plastic parts for semiconductor manufacturing. These techniques ensure accuracy and consistency in the plastic parts, guaranteeing their reliability.

The form of these parts, influenced by factors like the plastic packaging process and the form of solder joints, also significantly impacts component reliability.

The Most Common Plastics Used in Semiconductors

Several plastics, each with unique properties and advantages, are commonly used in semiconductor manufacturing:

• PEEK
• PAEK
• PEI
• PPS

In the following sections, we'll explore the specific properties of these plastics and how they enhance the overall performance and functionality of semiconductors.

The remarkable properties of PEEK include:

• High-temperature resistance
• Exceptional mechanical strength
• Chemical stability
• Minimal moisture absorption
• Superior chemical and wear resistance
• Effective static electricity management

PAEK stands out in the semiconductor industry due to its high-temperature strength, robust mechanical properties, FDA compliance, chemical resistance, advantageous electrical properties, and flame retardance.

PEI improves semiconductor functionality by offering high strength and excellent electrical properties, even at elevated temperatures.

PPS is favored in semiconductor manufacturing for its extraordinary resistance to high temperatures, chemicals, and mechanical strength.

PEEK

PEEK is ideal for semiconductor manufacturing due to its outstanding mechanical properties, which include:

• Resilience
• Durability
• Strength
• Resistance to wear, moisture, and chemicals
• Dimensional stability
• Stiffness

These attributes make PEEK a preferred choice for advanced technology applications.

PEEK’s exceptional chemical resistance and ability to maintain strength at elevated temperatures make it ideal for the challenging conditions in semiconductor processing. PEEK’s high temperature tolerance, reaching up to 260°C/500°F, is crucial in applications where stability and performance at elevated temperatures are essential.

PEEK for semiconductor applications can be manufactured through injection molding, additive manufacturing, or CNC machining, offering repeatability and precision for parts with tight tolerances.

One common use of PEEK in semiconductor materials is CMP retaining rings, which we detail here.

PAEK

PAEK boasts high-temperature resistance, exceptional strength, chemical resistance, and low moisture absorption, making it suitable for semiconductor manufacturing. It is used in applications such as screws and fasteners in wet benches and components for semiconductor manufacturing equipment.

Typical processing techniques for PAEK in semiconductor manufacturing include deposition, removal, patterning, and modification of various components. Challenges in using PAEK include reducing leachables, minimizing contamination, and enhancing product lifespan by decreasing wear and improving sealability.

PEI

PEI plastic offers resistance to high temperatures due to its mechanical strength, stability, and favorable chemical and temperature resistance. It maintains stiffness and impact resistance even in elevated temperature conditions, making it suitable for high-temperature applications.

PEI ensures excellent dimensional stability due to its resistance to thermal deformation, low coefficient of thermal expansion, and minimal moisture absorption. These factors are critical for maintaining precise dimensions in various environmental conditions.

PPS

PPS is a cost-effective material for semiconductor manufacturing, known for its exceptional thermal properties and chemical resistance, making it well-suited for the industry's needs. Benefits of PPS include:

• Exceptional thermal properties
• Chemical resistance to acids, alkalis, ketones, and hydrocarbons
• Outstanding structural performance in harsh chemical environments

PPS exhibits the following properties:

• High thermal stability, retaining mechanical strength and rigidity at temperatures exceeding 200°C
• Chemical stability at elevated temperatures
• Resistance to a wide array of chemicals

PPS also offers:

• High dimensional stability
• Exceptional mechanical strength, even at elevated temperatures
• Outstanding strength-to-weight ratio compared to other plastics used in semiconductor applications

Ensuring Quality and Consistency in Plastic Part Production

Ensuring the quality and consistency of produced plastic parts is critical. In the semiconductor industry, Copy Exact standards are essential for preventing variations in part dimensions or material composition, ensuring high quality and consistent output. Coordinate Measuring Machines (CMMs) help guarantee the accuracy of plastic parts by validating dimensional precision, identifying imperfections, and ensuring compliance with stringent quality standards. Additional reading:

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The quality of plastic parts in semiconductor manufacturing is also assessed using testing fixtures, such as test sockets and inspection fixtures, and through thermal quality testing for components. These evaluations ensure that parts perform reliably in real-world conditions.

Copy Exact Standards in Plastic Manufacturing

Copy Exact standards involve requirements and procedures designed to ensure precise replication of a product or component with identical specifications. While there is no universal industry standard, Copy Exact manufacturing requires rigorous contamination control and thorough verification measures to achieve the desired replication.

Implementing Copy Exact standards involves aligning physical inputs, training and qualifying personnel, and maintaining accurate documentation. Upholding these standards in plastic manufacturing for the semiconductor industry presents challenges, such as stringent environmental considerations, precise control over molding and machining procedures, and ensuring components are free from particles and impurities.

Coordinate Measuring Machines for Accuracy

A Coordinate Measuring Machine (CMM) is crucial in producing plastic parts, used to assess the physical geometrical attributes of an object and verify adherence to design parameters. CMMs operate on two primary principles: employing a mechanical probe that contacts the object for measurements and using a coordinate system to define the object's position and orientation.

CMMs offer exceptional precision, measuring attributes down to a micrometer. They assess physical features, workpiece conditions, environmental influences, and surface properties.

Various types of CMMs are used in plastic part manufacturing, including:

• Bridge CMMs
• Cantilever CMMs
• Gantry CMMs
• Horizontal arm CMMs

Each type suits specific measurement requirements and production configurations.

Designing Plastic Components for Semiconductor Applications

Designing plastic components for semiconductor applications requires balancing various factors. By selecting the appropriate plastic package for the application, utilizing high-performance polymers to achieve desired characteristics, and optimizing production processes to minimize costs while maintaining or improving part quality, designers can achieve this balance. The design of plastic components for semiconductor applications focuses on performance, requiring high-performance plastics that offer excellent dimensional stability and chemical resistance to meet semiconductor manufacturing demands.

Following ISO standards is crucial when designing and manufacturing plastic components for semiconductor applications. Standards like ISO/TS-16949 and ISO 15494:2015 ensure quality and uniformity in design and manufacturing procedures.

Primary considerations include:

• Evaluating material properties
• Ensuring components withstand harsh chemicals and static electricity
• Considering precise dimensions for the application

Balancing Cost with Performance

To balance cost and performance in designing plastic components for semiconductors, factor in:

• Material considerations
• Performance requirements
• Dimensional attributes
• Target cost

Optimizing part dimensions to minimize material waste during machining is one approach. Additionally, using high-performance plastics with superior dimensional stability helps maintain tight tolerances across temperature variations.

Design plays a pivotal role in balancing product performance and cost-effectiveness. The use of high-performance polymers significantly contributes to achieving this balance. However, more intricate designs and manufacturing processes can increase costs, so considering an appropriate model for these processes is crucial.

ISO Standards in Design and Manufacturing

Relevant ISO standards for plastic component design and manufacturing include ISO 20457 for manufacturing tolerances, ISO 68000 for safety requirements of injection molding machines, and ISO 13485 for manufacturing quality standards. ISO standards impact the global semiconductor industry by defining requirements, facilitating collaboration between customers and suppliers, managing continual improvements, ensuring product quality, and meeting regulatory requirements.

To obtain ISO certification for manufacturing plastic components, a company must implement requirements specified in the relevant ISO standard, typically requiring six months to a year for registration.

Custom Solutions for Advanced Semiconductor Needs

As the semiconductor industry evolves, custom solutions are essential to meet new demands. These include:

• Manufacturing solid-state memories (DRAM)
• MOSFETS
• 3-D NAND flash memories
• DSPs
• MPUs
• Advanced chip packaging using chiplets
• Creating custom packages to fulfill specific demands.

Customization enhances semiconductor performance by using specialized equipment for silicon wafer processing, providing performance advantages and differentiation. Tuning custom silicon to precise application needs further boosts performance.

Partnering with Experts in Plastic Manufacturing

Collaborating with plastic manufacturing experts like Atlas Fibre offers numerous benefits, including improved cost-effectiveness, operational efficiency, and component longevity. Atlas Fibre provides exceptional strength, chemical resistance, weight reduction, design flexibility, advanced equipment, stringent quality control, and personalized services tailored to specific requirements.

Atlas Fibre ensures high standards in its plastic manufacturing process for semiconductors through meticulous batch and sheet testing to control quality and assess properties. As a key supplier of thermoset composite materials, the company provides the largest selection of in-stock materials in the United States, including crucial carbon fiber thermoset plastics for semiconductor manufacturing. Contact us today!

Summary

In conclusion, plastics play an indispensable role in semiconductor manufacturing due to their precision, purity, and resistance. The most common plastics in this industry include PEEK, PAEK, PEI, and PPS, each with unique attributes. Ensuring quality and consistency in plastic part production involves methods like Copy Exact standards and using Coordinate Measuring Machines. Balancing cost with performance and adhering to ISO standards are crucial in designing plastic components for semiconductor applications. Finally, custom solutions and expert partnerships significantly enhance semiconductor performance and efficiency.

Frequently Asked Questions

Which plastic is used in semiconductors?

Semiconductors often use HDPE (high-density polyethylene), PEEK, PAEK, PPS, or PEI for their strength, resistance to acids, and versatility in creating quality and pure plastic parts.

Is plastic a good semiconductor?

Generally, plastics are insulative but can have fillers or additives that make them conductive or suitable for ESD applications. This transformation allows plastics to be used effectively in these fields.

What measures are taken to ensure quality and consistency in plastic part production?

To ensure quality and consistency in plastic part production, we implement Copy Exact standards and utilize Coordinate Measuring Machines. These measures help maintain high standards and accuracy in the production process.

What considerations are important when designing plastic components for semiconductor applications?

When designing plastic components for semiconductor applications, it’s crucial to balance cost with performance and adhere to ISO standards to ensure quality and reliability.

PEEK bearing materials with excellent heat resistance and durability

Unfilled PEEK natural is a balanced material for high-temperature environments where non-lubricated sliding and non-contamination are essential. However, some applications require special PEEK bearing grades like TECAPEEK PVX black, which contains multiple fillers (graphite, carbon fiber, and PTFE) to meet various criteria:

• Low coefficient of friction
• Improved heat dissipation (reduced frictional heat)
• Enhanced strength and wear resistance

This bearing-grade material is suitable for harsh environments ranging from 100 to 300°C. PEEK is used where conventional materials (POM, PA/Nylon) would fail. Due to its excellent sliding characteristics, PEEK is used in gears, bearings, sliding bearings, and many other applications. To avoid thermal overload of a bearing, frictional heat must be dissipated quickly from the sliding surface. The better the thermal conductivity, the faster the heat dissipation and the reduced risk of overheating. Fillers like carbon fiber and graphite make TECAPEEK PVX black a superior bearing grade with improved thermal conductivity.

The sliding behavior always depends on the overall sliding system and parameters like the sliding partner, load, sliding speed, surface roughness, and temperature.

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