ELCAN Málaga Takes a Lead in Lead-Free Technology

ELCAN Optical Technologies, a unit of Raytheon Network Centric Systems, is a fully integrated firm specializing in the design and manufacture of complex optoelectronic systems and subsystems for the commercial, defense, optical communications and automotive markets.  ELCAN’s European optoelectronics facility is located on the beautiful Costa de Sol at Málaga, Spain.  The Málaga operation was a former Hughes micro-electronics facility that Raytheon acquired in 1997.  It has a successful history in manufacturing for the automotive and defense industries.  As a result of this merger, ELCAN has the ability to combine their traditional precision optical capabilities of the ELCAN Midland facility with the electronics expertise in Málaga.  As part of the ELCAN group, the Málaga facility has transformed from a generalized electronics manufacturing facility into an integrated optoelectronics operation, providing high level electronic and optoelectronic design, development and assembly.  ELCAN Málaga is now a one-stop shop from design to mass production in the procurement of CCA’s, precision optoelectronics, RFID and microelectronic components positioned to serve the growing European Union markets.

The ELCAN Málaga technologies for PCB assembly and microelectronics fabrication include:

• Electronic design, prototyping and design for manufacture;
• High speed SMT (Surface Mount Technology);
• Fine pitch placement;
• BGA and Flip-Chip;
• Automated insertion;
• Reflow;
• Nitrogen Atmosphere Wave Soldering;
• Chip-on-Board, Chip-on-Flex and Multi-Chip Modules; and
• Automated optical, x-ray, inspection and circuit testing.

In February 2003, a directive was adopted requiring all European electronics companies manufacturing industrial and commercial electronic products to discontinue the use of harmful and hazardous materials by July 1st 2006.  The legislation,  “The Restriction of Use of Certain Hazardous Substances” Directive (RoHS), is a directive of the European Parliament and The Council of the European Union.  RoHS ensures that any new large and small household appliances, IT equipment, telecommunications equipment (although infrastructure equipment is exempt in some countries), consumer equipment, lighting equipment (including light bulbs), toys, leisure and sports equipment, automatic dispensers and electronical/electronic equipment put on the market does not contain lead, mercury, cadmium, hexavalent chromium, polybrominated biphenyls or polybrominated diphenyl ethers.  The RoHS directive applies to products in the EU, whether manufactured there or imported.  Companies must supply a Declaration of Conformity.  As of July 2006, failure to comply will result in stiff penalties.

ELCAN Málaga made the strategic decision to offer lead-free products before the compliancy date.  Offering lead-free products early allowed ELCAN customers to remain competitive.  The challenge – to develop an alternative to the 63:37/tin:lead solder, and the subsequent necessity for higher temperatures, without compromising product quality.

One of ELCAN Málaga’s concerns with respect to the move to lead-free soldering is a phenomenon known as “tin whiskers”.  Tin whiskers are a crystalline metallurgical occurrence where the metal grows tiny, filiform hairs.  The cause of this “whisker” growth is not understood comprehensively, but seems to be encouraged by compressive mechanical stresses that can be thermally induced.  Whiskers can cause short circuits and arcing in electrical equipment.  (Tin whiskers caused the failure of the Galaxy IV satellite in 1998.)  Despite extensive qualification testing of the new process, there is no way to be certain that the new process will be as reliable as the traditional tin/lead alloy.  This concern is not urgent for the manufacture of consumer electronics, but vital to the defense and medical industries.

With this concern in mind, The defense industry’s Monitoring and Control Instruments, medical electronics and all medical devices (with the exception of implantable and infected products) are not covered by RoHS – for now.  The EU is now examining both of these business areas and amendments to this directive may soon be delivered.

ELCAN Málaga has made significant capital investments to develop and maintain both the traditional solder and the new lead-free processes continue to meet the needs of all electronics sectors.  ELCAN Málaga will still be able to meet the needs of our medical and military customers while simultaneously servicing those clients covered by the RoHS directive.

For more information, visit http://www.elcan.com/, Email Us or Request your Custom Solution.