Circuitry and plated holes can become damaged during processing and rework. One method for repairing damaged circuitry uses the Foil Jumper Method. This method uses pure copper Circuit tracks. The replaced conductors are the same size as the original. This IPC recommended technique is preferable to making circuitry repairs with jumper wires because it more closely duplicates the original fabrication process.
Damaged plated through holes are repaired using eyelets. We have also refined an IPC recommended method for repairing damaged plated holes on multilayer circuit boards that have inner layer connections.
Preview the slides below to discover how we do it.
This image shows common circuitry and conductor damage, including damage to plated holes. During processing it's common for this type of damage to occur.
We evaluate the extent of the damage and determine the labor time and materials costs. We confirm to you the full cost before we proceed. Once you give us the approval, we schedule the work.
Step 1: We remove the damaged circuits trimmed back to a point where the circuit has a good bond to the circuit board surface. We remove all loose material and clean the area.
Step 3. The circuits we use are pure copper and can be formed to match the original circuit path. As needed we carefully bend and shape the Circuit Track.
Step 4. We form the final shape and hold the replacement circuit in place with high temperature tape. We then lap solder the ends to the existing circuits as needed.
Step 5. We overcoat the new circuit with high-strength, high-temperature epoxy. We often add a color agent to the mixed epoxy to ensure the repair is a cosmetic match.
Step 6. For repair of plated holes we drill out the damaged and select an eyelet that matches the plated hole dimensions. If the plated hole has internal connections we use an alternate procedure.
Step 7. We insert an eyelet into the hole. If a new circuit is required, the new circuit may extend into the drilled hole and the flange of the eyelet will secure the new circuit in place.
Precision eyelet presses are use to set eyelets.
Eyelet tooling uses a roll form configuration to set eyelets producing a flat flange on both sides of the circuit board.
This photo shows the repaired circuits and plated holes. This high conformance level repair process follows documented IPC guidelines to ensure the repair is reliable and robust.
Circuitry and Plated Hole Rework
Occasionally errors in the circuit board fabrication process occur, or design changes are needed to upgrade circuit boards. Whatever the reason we can help you overcome the modification requirement. Common applications include adding gold edge contacts, rerouting signal connection, isolating vias and pads or adding an entire component footprints.