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Challenge
TESAT’s challenge was to develop an “Automated Microwave Factory" to manufacture complex highly integrated LTCC microwave modules within the frequency range 2 to 77GHz, 24 hours per day including a manless overnight ghost shift. TESAT wanted a high volume, high reliability, fully automated production line to build complex microwave modules with minimal labor required for competitive terrestrial products as well as for the commercial satellite market.
Solution
A team consisting of seven highly experienced engineers and technicians was put in place. Major tasks and responsibilities of the team were rapid prototyping, industrial engineering, development of assembly and test processes, development of advanced manufacturing technologies, and last, but not least, high volume series production.
By reducing the number of process variables to the very minimum and developing a series of robust assembly processes like plasma-cleaning, epoxy dispense, pick and place, eutectic die attach, wire-bonding, automatic optical inspection and electrical test, the team was able to ensure that all products were perfectly set up for automated series production.
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