bfksolutions.com

Even with cleanrooms and controlled environments, the problems associated with traditional manufacturing become magnified with manufacture of miniature, micro, and nano components.   Ed, “The Rocket Scientist,” likes to explain that as products become smaller and smaller, the surface becomes the product. 

The manufacture of miniature, micro, and nano-based products requires making rational, practical decision about cleaning processes.  BFK Solutions has decades of experience in successful micro and nano manufacturing.  

Nanodevice

The yield of a nanodevice was unacceptably low.  BFK Solutions reviewed processes and employee practices.  In an educational program, we explained issues to cleanroom operators.  We developed a set of practices to minimize contamination that were acceptable to both management and employees. We also reviewed the cleanroom design, the cleaning processes, and the general workflow.  We identified readily-correctable sources of contamination.   What is generally referred to as “cleanroom discipline” showed marked improvement.  The cleaning processes and workflow were also streamlined; yield improved.   

Specialized Microelectronics

The company was developing a specialized, advanced wafer fabrication process. Particulate contamination, wafer surface preparation, contamination control, and process scale-up were major concerns. In addition, regulatory constraints and company policy mandated replacement of some solvents. Modifying the process required extensive departmental cooperation, so that it was clear how the effects of a given process could impact subsequent operations. 

BFK Solutions conducted a site visit that included an educational seminar, brainstorming workshop, and a site audit. Process document and analytical test results were also evaluated. After extensive evaluation and incorporation of requirements of various department personnel, BFK Solutions recommended appropriate chemicals and equipment to optimize process flow and minimize contamination.