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Takatori Temporary Bonding Solutions

March 19, 2018

Developments in advanced packaging and 3D integration have driven the demand for better ways to work with ultra-thin wafers safely. The need to run thin wafers through processes beyond the standard post-grinding steps (like polishing, detaping and dicing) has driven demand for cost-effective ways to bond ultra-thin wafers to a carrier made of sapphire, glass, silicon, or other materials.

Many temporary bonding methods have featured spin-on adhesive, which requires complex, expensive machines.

In 2003, Takatori began offering its WSM-series machines, providing a unique temporary bonding solution featuring double-sided tape. Unfortunately, the double-sided tapes available at that time were not capable of surviving high-temperature processes, and this limited the appeal of Takatori’s new machine.

Fortunately double-sided tapes have continued to evolve, and today both Nitto’s Revalpha and Sekisui’s Selfa tapes can survive higher temperatures while maintaining good adhesion and allowing for easy debonding.

Today, Takatori’s WSM-100 offers a cost-effective solution for temporary bonding. The machine uses a combination of atmospheric lamination and vacuum bonding, and works with many types of carrier wafers and different tapes. Today’s tapes are either heat-release or UV-release, and both types are supported by Takatori’s debonding/mounting tool, the WSM-200.

Call GTI Technologies today at +1 (203) 929-2200 or contact us via the web at gti-usa.com to find out how the WSM-series of machines can address your temporary bonding needs.

Filed Under: Uncategorized

New Concepts for Cutting Core Materials

March 5, 2018

Diamond wire, originally developed for cutting hard, crystalline materials, offers a new solution for cutting core materials. The technology provides numerous advantages over traditional technologies including multi-axis machining centers and bandsaws. It is an effective tool for cutting a wide variety of materials quickly and efficiently.

Diamond wire technology:

1. Reduces Damage – Diamond wire cutting, while effective for even the hardest materials, is a relatively gentle process when compared to the more aggressive, traditional machining methods. Diamond wire uses a very fine abrasive on a thin wire, and even fast cuts can leave behind pristine edges and surfaces. Delicate feathered edges are possible, with honeycomb cells left completely intact even on the sharpest angles.

2. Minimizes Kerf Loss – Diamond wire is thin, (the current standard for cutting composites is only ~0.350mm in diameter,) – minimizing material loss. Customers get more parts out of a given quantity of core material with diamond wire cutting, lowering costs.

3. Offers speed – Despite the gentle cut and thin wire, diamond wire technology cuts materials at high speed, even in thick and dense cores. The use of a multi-axis industrial robot with the Takatori TWR-300 Robot Wire Saw opens the door to cutting complex shapes on a relatively inexpensive platform, saving time and money.

4. Generates Fewer Particles – Diamond wire cutting requires no coolant and only generates a small amount of fine dust.

While new to the composites industry, diamond wire technology has been used extensively in industrial applications for almost 20 years, making it a mature, reliable technology. Contact GTI to learn more about how diamond wire can help you with your application.

Filed Under: Uncategorized

What Is Diamond Wire?

February 19, 2018

Diamond wire, originally adopted for mass production by the sapphire industry and then by the silicon industry, significantly increases the productivity of wire sawing and provides downstream benefits as well. It also offers an interesting option for cutting composite materials: demonstrating advantages when cutting both core materials and carbon fiber.

Diamond wire is made in a number of ways, but the most common way is by attaching fine diamond particles to steel wire through an electroplating process. Wire manufacturers provide the nominal diameter of the wire and the diamond abrasive, as well as the core diameter (the diameter of the wire itself) and the size of the abrasive particles. While the most commonly used wires don’t offer high diamond density, wire makers can fine tune the abrasive density and some offer particularly high-density diamond wire for special applications. Resin-bonded diamond wire is also available, though it is less common.


Advantages of Diamond Wire: Fast, Clean, Gentle

The first advantage of diamond wire is speed. Conventional slurry-based wire sawing can be slow when cutting very hard materials. Diamond wire offers substantial improvements in speed, increasing the productivity of each machine.

Next, diamond wire is clean. The coolant required for cutting is primarily water, with a small amount of surfactant added. This makes for easy set up, and also makes it easy to reclaim material lost during the cutting process.

Finally, while diamond wire is more aggressive than slurry for cutting crystalline materials, it is a relatively gentle process for cutting composites. It allows for very fine edges on core materials, less deformation of metallic core, and when cutting carbon fiber it offers lower damage, less delamination, and higher surface quality.

Contact GTI today to learn more about how diamond wire may help you with your applications.

Filed Under: Uncategorized

Takatori Annual Distributor Meeting

February 2, 2018

This week Takatori conducted their annual distributor meeting a t their factory in Kashihara City, Japan. GTI was there along with distributors from across Asia to learn about Takatori’s latest innovations and to hear about markets all over the world.

In the multi-wire saw business Takatori presented the new MWS-620DD, a large capacity multi-wire saw built for high production slicing of hard materials. The machine features a longer work envelope, highly rigid construction, and host of other improvements. While originally designed for diamond wire cutting of sapphire ingots, the machine will soon be available for slurry slicing as well, opening the door to new possibilities.

The semiconductor division showed the latest in solutions for advanced packaging applications. As many companies move forward with WLCSP processes Takatori continues to show new machines to meet their demands. They remain the most flexible manufacturer of lamination, de-lamination, and mounting tools, willing to work closely with customers to create the best solution for their application.

Filed Under: Uncategorized

Installation guide for a Takatori Wire Saw from GTI

December 15, 2017

You’ve made the investment in your new Takatori wire saw, and now we’re here to help you make that machine a success. Good support is key, and with GTI it starts even before the new wire saw arrives. Here’s a guide to the logistics of receiving and installing your new wire saw. These instructions must be followed to ensure a smooth installation and avoid any warranty issues. Please follow them closely.

Preparing for the Arrival of Your New Wire Saw

Prior to the arrival of your new machine there are some steps to be taken to ensure a smooth startup.

1. Select an area where the machine will be placed. Ensure that the floor is ready for the weight of the machine, and that there is adequate clearance around the new wire saw to allow for the chiller units, slurry pot, and opening of maintenance panels. GTI will provide a floor plan for your machine.

2. Prepare all utilities for the machine. Utilities required may include (but not be limited to):

  • electrical lines
  • pneumatic lines
  • water lines
  • exhaust venting hoses

Make sure that the capacity of each utility is appropriate for the machine. Lines should be ready to be hooked up when the machine arrives. The GTI engineer will perform the hookup during installation.

3. Order all machine consumables so your are ready for the startup. This includes:

  • Slicing Wire
  • Slurry abrasive
  • Slurry vehicle
  • Mounting blocks
  • Mounting glue

GTI can help you with all of your consumable needs, contact us at +1 203 929 2200.

4. Prepare product material. Make sure to have ingots ready to be sliced when the machine is installed.

Shipping & Transporting your Takatori Wire Saw

GTI will arrange for the wire saw to be transported to the port of entry. You are typically responsible for shipment once the saw clears customs, but we can also arrange shipment directly to your site, should you choose this option at the time of purchasing the wire saw. This is arranged by a GTI Technologies Customer Service Representative as soon as we receive word as to when the saw will be ready for shipment.

If your company is arranging shipment from the port of entry to your facility, please make sure to arrange for an air-ride truck. Prior to the machine’s arrival, make sure that you have the ability to off-load the machine and move it into place. When the crate arrives, make sure to check it for any damage during shipment; make a note and take photographs of any damage and inform GTI immediately.

If you are accepting the machine after a run-off at the factory, shipping will be scheduled for as soon as practical after the run-off. If you have a preferred carrier you would like to use, please let us know at the time of order placement in the Purchase Order. Otherwise we will arrange all shipping and transportation details through our normal channels.

Takatori Wire Saw Installation Checklist

1. Dismantle crate.

2. Remove the Operator’s Manual and read the installation instructions carefully. [Please note, the manual can be provided prior to shipment in pdf format, should you choose. Just ask your Customer Service Representative.]

3. Check Packing List against the machine and accessories received, as well as against your original Purchase Order. Inspect all items visually for possible shipping damage. If you find any discrepancies in the order, or you find any shipping damage, please contact the GTI Customer Service Representative immediately by calling +1 203 929 2200.

4. Move the new machine to its desired location. [Leveling feet already there?]

5. Bring all utilities to the machine, but do not connect them yet. Utilities required may include (but not limited to):

  • electrical lines
  • pneumatic lines
  • water lines
  • exhaust venting hoses

On the first day of installation your GTI technician will double check all utilities for compatibility before connections are made. If you have any questions, please contact us immediately at +1 203 929 2200.

6. Clean the new wire saw machine of all rust preventative materials and any residue that may have accumulated during shipment.

7. Have all machine consumables in place and ready for use. This includes:

  • Slicing Wire
  • Slurry abrasive
  • Slurry vehicle
  • Mounting blocks
  • Mounting glues
  • Sufficient workpieces for testing

If you have any questions as to what is required, contact your GTI Customer Service Representative.

Our goal is a smooth installation that puts you into production as soon as possible. These instructions avoid delays when our technicians are onsite (which could result in additional charges) and help to ensure your warranty coverage.

Customer Service & Technical Support

Should you have any questions or issues once your new Takatori Wire Saw is installed, GTI is here to help. Please contact our Technical Support Team at +1 203 929 2200, Monday through Friday, 8 am to 5 pm EST.

Filed Under: Product

Cutting Composites with Diamond Wire

December 8, 2017

Diamond wire has been used for many years by companies looking to cut very hard materials, particularly sapphire, into thin wafers. Producers needed a fast cutting method that minimized material loss and damage, and diamond wire delivered.

Takatori has taken decades of wire saw experience in hard materials and created a small, flexible wire saw designed to be mounted on an industrial robot to cut composite materials. This is a new cutting method for composites, and it offers certain advantages.

Reduced Damage

One of the greatest advantages of diamond wire is the reduction in damage. When cutting honeycomb materials, aggressive cutting methods can damage the workpiece. Delicate feathered edges can be difficult, particularly when cutting aluminum core. diamond wire can deliver uniquely low-impact cutting, delivering precise results even when cutting the most delicate parts. The reduced damage during cutting also reduces the need for hand-finishing, saving material and time.

When cutting carbon fiber, diamond wire cutting delivers a high quality cut while almost eliminating delamination, leaving behind a clean, straight cut without hanging fibers.

Diamond wire cutting can also be an effective solution for cutting sandwich panels, as it quickly cuts through both carbon fiber and various core materials.

Clean Cutting

Cutting with diamond wire saves time down stream not just by delivering high quality cuts, but also by being clean. Particle generation is minimal, and the minimum damage to the workpiece also means less particulate. Cutting is also usually done dry, without coolant, eliminating another potential source of problems.

Speed

Cutting composite materials with diamond wire has certain speed advantages. The machine can cut through various core materials quickly and efficiently, with the multi-axis robot providing a capable platform for making complex shapes. Some geometry can be cut much more efficiently than with competing technology.

When cutting thick carbon fiber some real advantages become apparent. In addition to the excellent cut quality, diamond wire is capable of cutting quickly through even very thick CF, and cutting prepreg is also possible.

Cost

Diamond wire is competitive with other cutting technologies, and the constant pressure from the sapphire and solar markets for higher quality at lower prices will continue the downward path of diamond wire pricing.

We look forward to working together with you to see how diamond wire cutting can help your composites application.

Click here for more info: https://gti-usa.com/product/robot-wire-saw/

Filed Under: Uncategorized

Takatori Slicing Solutions for R&D and Pilot Production

December 4, 2017

The WSD-K2 and WSD-K3 deliver Takatori slicing quality and reliability for customers looking for smaller-scale slicing capability. Whether used for pilot production, material R&D, or process development, the K2 and K3 offer a powerful, flexible solution to customers not yet ready for a production-scale machine. It also finds use at production facilities for development purposes, cutting seed crystals, and other applications that would otherwise occupy a production machine.

Why choose this machine over the competition?

The WSD-K2 and K3 are first and foremost Takatori wire saws. Takatori has been building multi-wire saws for 30 years, and is the industry standard for numerous applications. While small, the K2/K3 still offers Takatori quality, both in build and output. A robust control system allows for detailed, multi-step programming of slicing parameters, and the available Y/Theta table allows for multi-cut programming for cutting longer pieces or for dicing applications. The K2/K3 can be operated in single wire or multi-sire modes, and can quickly be switched between the two. Use wire from any manufacturer, including very thin wire. The WSD-K2 and K3 are quiet, capable, and dependable.

Why choose a smaller wire saw over a larger wire saw?

Sometimes a small saw is all you need. With numerous materials the crystals are small, whether due to manufacturing constraints or demand, and a large wire saw is not feasible. For other companies that already have multi-wire saws, they may not want to sacrifice production time for small-scale development or cutting seed crystal, making a small wire saw a good investment.

What can it do?

The K2/K3 uses diamond wire to cut various materials, usually (but exclusively) monocrystalline materials for semiconductor, photonics, or optical applications. The WSD-K2 can cut materials up to 156mm in diameter, and the K3 up to 200mm in diameter, using diamond wire. The machine can operate with a single wire or multiple wires, depending on customer needs.

Click below for more information on how the WSD-K2 and WSD-K3 can help you.

WSD-K2

Filed Under: Uncategorized

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