Calumet Electronics was the very first printed circuit board manufacturing company to commercialize the revolutionary new Averatek Semi-Additive Process (A-SAP™) and offer the ability to manufacture 25-micron feature sizes with PCB technology. I am sitting down to discuss the A-SAP™ solution with Calumet’s Meredith LaBeau.
Tara Dunn: Hi Meredith, can you share a few thoughts on your initial reaction to this technology and what factors led to the Calumet Electronics decision to partner with Averatek?
Meredith LaBeau: Calumet Electronics was first introduced to this technology through an IPC APEX presentation in 2019. This presentation introduced a new technology that could be utilized to drop the SWaP (size, weight, and power) while still manufacturing printed circuit boards or other advanced packaging in the standard manufacturing and equipment ecosystem. There were many factors that went into the Calumet Electronics decision to partner with Averatek, but at the very top were the following:
- The elegance of the solution to advance electronics quickly for domestic advanced technology needs.
- The partnership-driven team at Averatek to launch the technology into the domestic marketplace.
- The intelligence and support of the Averatek team.
- The potential for Calumet Electronics and other PCB manufacturers to have an available solution that is competitive with – and exceeds – the solutions in low-cost regions of the world.
Dunn: You and your team are doing a fantastic job reaching out and starting discussions with companies that have a need for these fine feature sizes. Throughout these discussions what are a few things that stand out to you, regarding market reaction and receptiveness to a new technology?
LaBeau: In all the discussions, what stands out most is the dire need for a technology that can achieve fine lines and spaces, while also utilizing some of the most advanced HDI features, along with extremely low loss material. These customers often must look overseas for manufacturing, which comes at a cost: long lead times, or re-designing the boards to meet the current domestic technology, often dumbing-down the backbone of the electronics system.
The Averatek process provides a robust, reliable, and elegant solution to meet the current and next-generation demands sought by the electronic system designers. These customers, regardless of the end-use market, require advanced PCBs as they continue to advance the electronics requirements along with the IC substrates. The market is ecstatic about the potential of this technology, providing light at the end of the tunnel for many.
Dunn: This is an excerpt from you in the A-SAP™ community of interest kick off video.
“The use of this innovative and transformative manufacturing method requires a new approach to design: with manufacturing instead of for manufacturing. Together, the designer and manufacturer can develop a collaborative approach, to Drop the SWAP – while increasing the reliability and robustness of the PCB for next-generation electronics systems.”
I often hear you impress on people that collaboration is critical in order to utilize the full potential of the A-SAP™ technology. How do you facilitate this high-quality communication, and what is your advice for designers who want to get all the advantages of A-SAP™ capabilities?
LaBeau: When utilizing a transformative manufacturing process, one must fully understand its advantages, as it applies to both design and the product requirements. With a market-changing technology, the manufacturer and designer must work in collaboration to gain all the benefits – while not increasing the cost.
The Averatek process allows a designer to simplify designs by using finer traces and spaces, greater line width control and impedance control. If the designer understands this, you can re-set the technology curve: simplifying designs in order to make the process and end-product more reliable and robust, while reducing risks of lead time or yield delays.
Dunn: Not only has Calumet Electronics invested in Averatek’s A-SAP™ process, but you have also been busy bringing in new materials, new process capabilities, new equipment and even a facility expansion. It is clear Calumet has a vision for the future. Do you want to share that vision and some of the exciting new capabilities?
LaBeau: Calumet Electronics does have a driving vision for the future: to advance the technology within the electronics ecosystem, through a combination of standard and new technologies, in partnership with OEMs and electronics assemblers to compete on the world stage. We want to bring the United States back to designing and manufacturing the most state-of-the-art printed circuit boards to meet the rugged domestic demands. In concert with this vision, is also our goal to bring engineering back to focus on PCB manufacturing, by working in collaboration to advance Manufacturing Readiness Levels (MRLs) of our customers’ product – from concept to volume production.
Calumet is focused on developing a world class staff to meet the technological needs of the electronics supply chain. In addition, we are focused on the PCBs that must be made domestically, which include applications for RF, microwave, beamforming, high precision tolerancing and fine lines and spaces.
Dunn: One thing that is clear when visiting Calumet Electronics: the pride in and support for the community. Along that theme, I would like to ask a more personal question. I am fascinated by one of your extra-curricular activities, serving as Director for a 150-mile dogsledding race. Can you tell us a little about that?
LaBeau: Living in the Copper Country in Upper Michigan, you come to really understand the concept of community. The harsh winters teach you to dig in, work hard and support your neighbors. This sense of community development endeared me to an organization, the CopperDog 150. This organizational utilizes a sled-dog race to showcase the natural winter beauty around the Copper Country as well as bring folks out together in the community to cheer on the rugged toughness of sled dogs. I joined the group in 2010 and within a year was assisting the current race director on every facet of a large-scale race and community event. This director happens to now be my boss and mentor, Todd Brassard, our COO. I eventually took over the reins. For many years I have enjoyed working with these unsung athletes, but most importantly breathing life into the sleepy towns of the Keweenaw Peninsula – to bring in vital tourism and increasing pride of our communities!
Dunn: Meredith, thanks for taking time for this short interview. For those interested in learning more about Calumet Electronics, what is the best way to reach you?
LaBeau: Thanks for taking time to speak with me today, Tara. Those who are interested in learning more can reach out to me via email at mlabeau@calumetelectronics.com.