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Blog | Manufacturing Solutions


Impacts of Manufacturing Tolerance on Filter Performance and Yields

Written by Mark Stanley - RF Product Manager
Posted on January 11, 2018 at 2:58 PM
Understanding the difference between modeled performance and test data is often the most challenging part of an RF filter or microwave filter build. This difference can be broken down into two parts – modeling inaccuracies and manufacturing tolerances. The possible sources of modeling inaccuracies are vast and won’t be addressed here. The various impacts of manufacturing tolerance, how to predict them, and tune around them, are issues we can work to correct. Two existing filter designs will be used as examples – A 3-port LC diplexer, with passbands from 100-500MHz and 700MHz-6GHz, and a suspended substrate distributed element broadband bandpass filter, with passband from 2.5-6GHz.

Capacitor Tolerance

The capacitors used in the LC diplexer design are +/-5% tolerance over nominal. Each capacitor forms a pole in the pass band, so the variance in frequency of each of the poles will affect the electrical response of the filter.  The response of the diplexer with nominal capacitance values is shown in Figure 1. A yield analysis of varying capacitor values over the +/- 5% tolerance is shown in Figure 2. It shows a yield of 65%, meaning 35% of manufactured parts would need to be tuned to meet the electrical spec.

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Manufacturing Issues with RF Circuit Boards

Written by Al Wright - PCB Field Applications Engineer
Posted on January 5, 2018 at 2:02 PM

If you’re a designer of RF or microwave printed circuit boards you’ve probably already selected a laminate material that is appropriate to your project, having based your choice primarily on the electrical requirements of the RF circuit, such as signal speed, loss rate etc. Be careful however not to overlook the fact that the specialty materials used in such designs also possess unusual mechanical characteristics; processing is different from that of normal FR4 boards.

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Finding New Battery Suppliers Without Losing Your Battery Design

Written by Ed McMahon - CEO
Posted on December 29, 2017 at 9:49 AM

Over the past several years there have been several instances where battery suppliers that manufacture the highest technology batteries have run into financial difficulties (think A123, Boston Power) or change their business model and no longer want to supply small/medium volume applications (Panasonic). This has created several problems for OEMs as they have designed these cells and have passed all of the certification testing for UL, EMI, CE and UN DOT 38.3.

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Battery Pack Manufacturing Tooling Cost Breakdown

Written by Shaun St. Onge - Process Engineer
Posted on December 19, 2017 at 1:25 PM

What do I get for my tooling dollar? This question (in one form or another) is one that gets asked frequently. Tooling is always a concern for the customer. It’s an added cost which cannot be converted to sales and ultimately, the bottom line.

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Custom Battery Pack Potting Process

Written by Anton Beck - Battery Product Manager
Posted on December 14, 2017 at 3:27 PM

This blog post provides a quick overview of what is involved in the battery pack potting process. Battery potting can greatly aid in stability and help to optimize the performance of your end product. Potting materials are used to provide mechanical reinforcement to housed-assemblies and to protect components against exposure to harmful chemicals, moisture, mechanical shock and vibrations, and other hazards.

Some additional benefits of using battery potting include low cost shells, hermetic like seal, and good electrical insulation.

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Epec's Battery Assembly and Test Procedures

Written by Marc Leclair - Vice President of Operations
Posted on December 12, 2017 at 3:43 PM

As a full service custom battery pack manufacturer, we prioritize providing our customers with the highest quality battery pack assembly while keeping you under budget. Many of the battery packs manufactured by Epec go into mission critical devices, which require nothing short of the highest quality rugged and reliable batteries. In this post we will look at three key aspects of Epec's US manufacturing that enable us to meet and exceed our goals.

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Securing Shipments During Peak Season

Written by Kendall Paradise - President
Posted on December 5, 2017 at 3:13 PM

We sit at the height of the largest e-commerce boom in the last twenty years. The way we approach shipping both personally and professionally is changing. Before the brick and mortar stores can even start playing their Christmas music, e-commerce sites are advertising shipping schedules to “guarantee delivery” for free shipping for various holidays. So what does this have to do with buying electronics? A lot.

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Proper Charging Of Lithium Ion Batteries For Shipping

Written by Anton Beck - Battery Product Manager
Posted on December 1, 2017 at 3:15 PM

This topic is mainly directed at shipping lithium ion batteries due to shipping regulations, but could also apply to Ni-MH where appropriate.

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Battery Pack Conformal Coating on PCBAs

Written by Mark Gaugenmaier - Battery Development Engineer
Posted on November 20, 2017 at 3:03 PM

It is important to be aware that certain applications will have battery packs that may be exposed to corrosive elements such as acidic, salt, and on occasion conductive substances and fluids. Over time this type of exposure can slowly corrode the PCBA, components, and solder joints. This type of corrosion can cause premature failure, short circuits, and or dangerous conditions that could lead to fire or even an explosion.

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The Right Way to Keep Costs Down For High Reliability HMI Devices

Written by Steven J Goodman - User Interface & Cable Assembly Product Manager
Posted on November 16, 2017 at 10:45 AM

Recently I spent the weekend at a family member’s home and experienced two failures of everyday human-machine interfaces (HMI) devices that truly perplexed me. One was a collapsed dome switch on a spa controller; the other was a graphical display error on a touchscreen coffee maker.

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