Dorset based specialist, Tecan Components Limited has developed a range of highly-accurate mask/foil manufacturing systems and frames – capable of meeting the most demanding requirements when evaporation-sputtering contacts onto quartz crystal oscillators and similar components, such as silicon substrates.

Traditionally, to produce the contacts on either side of a crystal substrate, three wafer-thin metal foils, or masks, are used – the crystal is sandwiched in the middle ‘spacer, or nest’ by the two outer masks, each of which has hole sizes exactlydefining the contact area to be vapour deposited. Tecan has developed a new method which uses only two sheets and significantly increased accuracy, while saving manufacturing time and costs.

This has been achieved by multi-level electroforming a single ‘stepped’ mask which takes the place of the centre spacer and one outer mask. In the past, masks have typically been produced by photo-etching, with tolerances of 25 microns – it has been possible to produce stepped masks this way – but not accurately enough for modern needs. Electroforming offers far greater accuracy, produces much sharper stepped edges and brings tolerances down to under 10 microns. This caters for both existing market requirements and changing trends towards increasingly smaller sizes and varied shapes – satisfying the need for ever-tighter tolerances while reducing manufacturing costs.

The company’s proven ability to offer both methods ensures established and new market requirements are catered for from a single source. Whether using new frames or existing frame arrangements, compatibility is assured. The company can produce whatever is required, from traditional three-mask sets, to the new twin-mask sandwich in magnetic stainless steel or nickel. The systems cost-effectively cater for development, prototyping, small, medium and large-scale production applications – affording consistently accurate results and easy maintenance.

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