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Thus, for a standard 18 in 24 in panel, 12 artwork changes are required to expose one side These systems have very high resolving capability and large depth of focus Again, glass artwork is used, but these smaller plates are easier to generate and use than in a scanning projection printer The magnified projection imaging concept was first demonstrated in the late 1980s with the SeriFLASH exposure tool, utilizing 436 nm illumination and a 5 in 5 in liquid crystal display as the phototool The image was magnified six times to expose an 18 in 24 in panel, but demonstrated photoresist definition was limited to 125 mm since the liquid crystal features were one-sixth of the final conductor widthThe equipment was subsequently modified for 365 nm exposure with a glass phototool to improve resolution Fifty-mm line and 63 mm space resolution has been demonstrated.

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27 The exposure time required is similar to that of contact exposure equipment With optimized optics, this may become a high-resolution tool that utilizes conventional photoresist and phototools..

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26.6.4.2 Laser Direct Imaging. The LDI method of exposure provides the ultimate in flexibility for customized pattern compensation factors and for engineering changes to the product design since it does not require a phototool. Systems introduced in the 1980s used an Ar+ laser with visible optics, requiring specialized photoresists that were sensitive to visible light. Improved Ar+ systems relied on the UV wavelengths, making it compatible with conventional photoresists. However, high-speed photoresists were needed to achieve the productivity for high-volume production. Concerns about the lifetime (3,000 to 5,000 hours) and power consumption (60 to 80 kW) of gas lasers led to development of solid-state laser systems at various wavelengths.28,29,30 The initial solid-state laser systems used 355 nm with a polygon mirror to scan the panel. Recently developed LDI systems have used digital mirror devices (DMD) instead of polygon mirrors and image at a wavelength of 405 nm. Filters are used to block 355 nm light, extending the lifetime of the DMD device. Due to the small size of the individual mirrors, about 1.5 microns, DMD technology provides better resolution than an 8,000 dpi polygon mirror system. However, the area coverage is smaller and several DMDs working in parallel are needed to expose a PWB panel. Systems have also been introduced that use no photoresist at all, laser ablating either tin for use as an etch resist or physical vapor deposition (PVD) copper on polyimide for use as a plating base.31,32 In addition to varying in laser type and wavelength, specific equipment designs differ in optics, either single- or multiple-beam operation; platen design; single- or double-side exposure; pixel shape; and spot size and resolution.

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Multiple-beam operation increases exposure productivity, a key requirement for economic feasibility in large-volume manufacturing. Target production rates for the various systems ranged from 60 to 180 panels per hour (18 in. 24 in. with 50 mm features). However, installed LDI systems have been used primarily for prototype and small-lot, quick-turn production of high-density boards. For these applications, savings are achieved due to artwork elimination and reduced setup time. For volume production of medium- to high-technology boards, it is possible to achieve an economic return through yield savings and the ability to produce designs that had not been technically or economically possible with conventional imaging.33 LDI technology makes it possible to scale the electronic data and and compensate for dimensional changes in sequential build-up (SBU) structures. Although the UV systems can expose conventional photoresist, use of high-speed photoresist is needed to maximize tool throughput. Most LDI systems use a flatbed platen design and can image both innerlayers and outerlayers. Systems with an external drum architecture, similar in design to laser photo plotters, are limited to innerlayers because the panel must have sufficient flexibility to conform to the drum (Fig. 26.18).The pixel shape can be either square or gaussian. Square pixels are made up

FIGURE 26.19 Computer simulation of aerial image for a 25 mm feature: (a) four 12.5 mm laser spots on 6.25 mm pixel spacing; (b) four 6.25 mm laser spots on 6.25 mm pixel spacing.

of many point sources of light and can theoretically achieve perfect stitching. However, in real systems there is intensity variation due to mechanical vibration and edge rounding. Gaussian pixels use a single-point source and may have less intensity variation. Due to the diffractionlimited nature of light, greater depth of focus can be achieved.34 Figure 26.19 illustrates that

FIGURE 26.20 Final image dimension as governed by spot size and addressability of a laser plotter or laser direct exposure tool.

imaging with a smaller laser spot size gives steeper aerial image sidewalls, increasing process latitude.35 In addition to spot size, addressability of the beam is important in determining the system resolution, as shown in Fig. 26.20. In selecting an LDI system, you must consider both the capital cost and operating cost. However, the critical factor is that the equipment combined with the photoresist material is capable of achieving both the resolution needed for the product mix and the productivity needed for the production volume. Photoresists for LDI are available that are compatible with the various metallization processes.36

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