An Integrated Tool for Rapid Prototyping of Electronic Circuits Using a Laser Direct Write Technique

A laser-based tool has been developed for the fabrication of electronic circuits. The tool integrates three separate functions on a single platform. These functions are deposition, laser processing, and laser micromachining. Deposition is accomplished by dispersing a target material in a thin layer over a transparent backing layer, holding the target material in close proximity to a receiving substrate, and irradiating the target material from behind with a short pulse UV laser. The UV pulse vaporizes a small amount of the material at the material/backing interface, thereby propelling the remainder of the target material toward the receiving substrate. Patterning is achieved either by translating the receiving substrate, scanning the laser beam, or a combination of the two. After transfer, most materials require some thermal processing: either oven baking or laser sintering. Fabricated circuits have included conductors (Ag, AgPd, AgPt, Cu), resistors (cermet and polymer thick film), and dielectrics (ceramic and polymer thick film). These materials have been patterned with feature sizes as small as 10 m and linear write speeds as high as 1 meter per second. The tool includes an integrated, near IR laser which can be operated both CW and pulsed for thermal processing. Laser sintering of metals, cermet resistors, and ceramic dielectrics has been demonstrated on low temperature, polymer substrates. The localized heating achievable with the laser allows the sintering or annealing of high temperature materials without damaging the underlying substrate. The tool includes a complete, state-of-the-art laser micromachining system, capable of milling recesses, drilling vias, trimming components, and excising circuits. No masks or phototools are required. No photoresists or wet chemistries are needed. The tool does not require a clean room environment. The combined functionality and speed result in a flexible and powerful tool for the rapid prototyping of circuits, and potentially, small scale production.