Large PCB Board Manufacturing and PCB Assembly

The team at Cybernetworks, LLC has extensive background in producing large and heavy PCB boards that are used extensively in Automatic Test Equipment (ATE) and Burn-In PCB board hardware.  These systems often require very tight PCB fabrication tolerances and have very unique PCB assembly characteristics.  We have experience with the most popular ATE systems in use.  This includes the Spea C600MX, C600MX-C, and Teradyne J750.  We also have experinece with Incal Burn-In oven hardware.  The Spea systems larger load boards measure out to almost 20" x 25", are .250" thick, can be up to 40 layers, and wiegh as much as 9 lbs before it's even assembled!  Many pick and place machines are not set up to handle such large and heavy PCB boards.  We can produce full, double-sided hardware sets: Probe Card, Load Board, and DUT PCB board manufacturing and assembly for these systems.  Most importantly, we do this at a significant cost savings to you over working with ATE system vendors directly and other large scale contract manufacturers without sacrificing quality.  

The short run PCB manufacturing and quick turn PCB assembly of these systems makes them naturally more expensive to produce from larger vendors with more overhead.  We are able to pass on to our customers considerable savings based on our small-business classification.  Our smaller size also makes us adept at rapid turn around for these builds.  Since we do not handle high volume builds that require dedicated assembly lines, we offer very rapid line change capability.  Depending on overall complexity, some fab and assemblies can be completed in as little as five business days!

We have excellent relationships with top PCB fabrication manufacturers who can produce ATE hardware and burn-in boards with the highest quality standards at exceptional prices.  We only use pcb board manufacturers located in the U.S.A. for all ATE and Burn-in hardware builds.  We believe this to be the best way to control quality and maintain on-time delivery.  Automatic Test Equipment printed circuit boards can be extremely complex.  Our preferred vendors in the U.S. can achieve the rigorous specifications for flatness and thickness tolerances demanded by these applications, along with excellent on-time delivery.  Completed fabrications are shipped overnight to our facility in Phoenix, Arizona for final SMT and through hole assembly*.  This allows us to be your main source for PCB fabrication and assembly on these systems.

Burn-In Boards or BIB systems have their own unique challenges in PCB manufacturing and PCB assembly.  The use of polyimide materials and lead free solder are a necessity in a burn-in board application where these boards are exposed to long term high temperatures in test cycles.   We are equipped to handle these specific needs for these types of PCB assembly.  It may seem obvious, but it is our policy to never use a Pb based solder in any burn-in application.  We have actually had to fix boards from other vendors who did not do this simple application.  A lead-free SAC305 solder insures the best overall quality and long term success of the assembly in the harshest of conditions.  The use of an FR4 material is another issue.  While FR4 is compatible with Pb free application, it is not the best material for burn-in PCB boards.  A polyimide material is the best choice due to its ability to withstand higher temperatures for long periods.  It has one draw back for PCB assembly, it likes to absorb air moisture.  This issue can be solved by baking the PCB board before assembly.  With our current Blue M bake oven we can accommodate polyimide pre-bake specifications to boards as large as 19.95" x 24.95" for safe SMT/reflow application.  Failure to pre-bake a polyimide board can result in delamination during SMT reflow, rendering your BIB useless before it's even complete.  

If you have an ATE or Burn-in system and need PCB manufacturing or PCB board assembly for these or other test applications please reach out to Cybernetworks, LLC today for a consultation and quote!

*Note: we do not provide spider attachment for probe card assembly.