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Comparison Between Laser Cut Stencil and Etching Stencil in SMT Industry
Comparison Between Laser Cut Stencil and Etching Stencil in SMT Industry
Comparison Between Laser Cut Stencil and Etching Stencil in SMT Industry
Stencils are used in the surface mount technology (SMT) assembly process to
apply solder paste onto printed circuit boards (PCB) before component placement.
The two main types of stencils used are laser cut stencils and etched stencils. This
article compares these two stencil fabrication methods in terms of accuracy, speed,
cost, durability, and other factors relevant to the SMT assembly process.
SMT stencils are thin metal sheets, usually made from stainless steel, that contain
apertures or openings matching the pads and patterns on the PCB. Solder paste is
applied over the stencil, then a squeegee blade is used to force paste through the
openings onto the PCB. After stencil printing, components can be accurately placed
onto the deposited solder paste.
Laser cut – Stencil apertures are cut by a laser. offers high precision and speed.
Etched – Stencil foil is coated with an etch resist, then chemically etched to remove
exposed areas. Lower cost but less accurate.
Laser cutting enables very precise stencil apertures, resulting in accuracy advantages
over etching.
Laser systems offer much faster stencil fabrication time compared to chemical
etching.
The slower etching process limits throughput. Lasers provide rapid turnaround which
is advantageous for prototyping and short run stencil needs.
Laser cut steel stencils generally demonstrate better durability than etched versions.
Lasers produce cleanly sheared stencil walls without etching roughness. This
improves paste release and cleaning while extending overall stencil lifetime.
Cost Analysis
Etched stencils have generally lower fabrication costs compared to laser cutting:
However, the extended lifetime of laser cut stencils offsets the higher initial cost over
repeated production use.
Laser cutting enables higher aspect ratio apertures than chemical etching:
High aspect ratios allow thinner stencils to print small features. This helps improve
solder paste release.
Design Flexibility
Lasers enable innovative stencil geometries to optimize print performance and solder
deposition.
This allows selecting specialized foils tailored to certain solder pastes or PCB pad
finishes.
Environmental Considerations
This makes laser cutting a cleaner and more sustainable stencil production method.
Conclusion
Laser cut stencils offer superior accuracy and lifetime for fine pitch SMT printing.
However, etched stencils can provide a lower cost option when resolution
requirements are more relaxed. Characteristics of the target PCB, components, and
solder paste should be evaluated to determine which fabrication method best suits the
application needs. Both technologies continue improving, but laser cut stencils are
expected to maintain advantages as electronics assemblies become progressively more
miniaturized.
The main benefits of laser cut stencils are higher precision, faster fabrication,
smoother aperture walls, greater durability, and broader material/design flexibility
compared to etched stencils. This makes them ideal for high density SMT printing.
For less demanding applications with larger features (>300 μm) and lower cost
sensitivity, etched stencils can be an acceptable alternative at a lower price point. But
laser cut stencils outperform etching for fine pitch work.
Precision laser cutting can reliably achieve ~25 μm accuracy and ±10 μm tolerance on
stencil aperture dimensions down to at least 150 μm. Lasers can cut apertures smaller
than 100 μm.
How many prints can be achieved with a laser cut vs. etched stencil?
Typical lifetime prints for a laser cut stencil exceeds 800, with some lasting 2000+.
Etched stencils average around 500 prints before degradation impacts process
capability.
Yes, lasers have demonstrated good cutting quality with foils down to at least 25 μm
thickness. Etching has more difficulty holding tolerances below 100 μm foil.
Related Posts:
https://www.raypcb.com/laser-cut-stencils-and-chemical-etching-stencils/