Roll-to-roll manufacturing is the process of unrolling a substrate on the assembly line, and this method has been followed for several applications across industries. At the end of the unrolling process, the product is already layered onto the substrate, where it can be rolled back again. At Automated Assembly, this concept is applied to making flexible assemblies such as SMT Flexible Circuit Assembly and Polyester RFID technology. We are capable of high-volume roll-to-roll assembly and products are far more reliable in thermally active environments than conductive adhesives. Contact us today to discuss your roll-to-roll flexible assembly requirements, and we will develop the best possible solution for you.
Overview of Our High-Volume Roll to Roll Assembly
Our roll-to-roll manufacturing process is all automated with optical recognition systems, saving us cost and time. It also eliminates the need for other expensive processes such as tractor feed systems and rotary punching. The length of our rolls is about 900 feet and only 12 inches in width. Our patented SMT-Flex® technology enables us to make high-volume roll-to-roll custom flex assemblies with the required control and precision, making the process reliable, fast, and cost-effective. Fully automated Roll-to-Roll (R2R) assembly lines are used to process 1,000 ft. master rolls of flexible circuits.
Offerings in Our Roll-to-Roll Assembly Process
This is what our high-volume roll-to-roll assembly process comprises.
- Using SMT-Flex®: SMT Flex™ is assembled using the patented SMT technology for high-speed automated placements. Fully automated Roll-to-Roll (R2R) assembly lines are used to process 1,000 ft. master rolls of flexible circuits. The continuous process of populating large rolls of substrates with circuits is fast, reliable and cost effective. To do this job, we use our Automated Assembly® robots, which are designed, fabricated and maintained in-house. We can place ICs, Flip Chips, and standard SMT components on a substrate in a fully automated Roll-to-Roll (R2R) assembly process.
- AOI: Testing is a crucial part of this assembly process and we use automated optical inspection to check the assembly thoroughly. We can pass the inspection data along to your robotic system for seamless manufacturing of the final product.
- Lamination: We offer lamination based on your requirements. Each roll is optically monitored for accurate lamination. While we commonly use optical lamination, our capabilities also include PSA lamination and top lamination. Heated lamination is available upon request. Electrostatic discharge (ESD) is monitored and dissipated on each film layer, resulting in high-quality lamination of SMT-Flex® Assemblies.
- Digital Printing: We offer digital printing in wide and narrow formats, and use good-quality inks rated for five years. We offer turnkey solutions for UV digital graphics on roll-to-roll formats with time-tested fade resistance. This makes it suitable for outdoor applications such as banners, and can produce photographic-quality RFIDs. Our production printer is capable of printing high print volumes for industrial applications, and built to withstand high duty cycles.
- Die Assembly: We offer wide format roll-to-roll die assembly on flexible substrates.
Benefits of Roll-to-Roll Assembly Using SMT-Flex®
Here are some benefits of using roll-to-roll assemblies, especially for high-volume requirements.
- This process facilitates continuous processing which is faster than batch processing, leading to reduced costs and time of manufacturing.
- It reduces manual labor as most of the process is automated and robots are used at many stages, such as testing and placing components.
- This process consumes less energy compared to batch processing and increases overall efficiency.
- Our advanced, state-of-the art manufacturing equipment offers the required precision, control, and quality.
- This method is especially useful for wearable devices, solar batteries, flex displays, various consumer electronics, diagnostic devices and other medical tools, sensors, and more.
Do you have requirements for high-volume flex circuit assemblies? We can be reliable partners regardless of your application requirements. Automated Assembly offers high-volume roll-to-roll Assembly for your flexible products. Feel free to contact us via phone or email if you need further information regarding our SMT-Flex® Roll-to-Roll assembly process using various substrates or wish to share your requirements with us.
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