Today’s consumers are accustomed to a certain level of imperfection in electronic devices.
An LED flashlight may fail. A laptop may no longer boot up the way it did just yesterday. But while these everyday equipment deficiencies may be accepted as part of modern living, the stakes are much higher when it comes to medical devices.
“Our customers in the implantable medical device industry demand the highest level of quality and precision,” said Todd Plaisted, director of marketing, KDF. “Equipment failure to perform is simply not an option for companies that produce pacemakers and defibrillators.”
Like all KDF sputtering tools, 844i Series systems are designed to meet demanding processing
requirements and feature an intuitive interface to monitor parameters.
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Founded in 1986, KDF is a leading supplier of physical vapor deposition (PVD) batch inline sputtering tools. These vacuum coating systems are used in the production of mainstream silicon, emerging materials, fl at panel displays, optical communications and medical devices. From headquarters in Rockleigh, New Jersey, KDF serves a global customer base and supports more than 3,300 systems in the field.
“More than half of the semiconductor fabs in the world use a KDF system in wafer processing,” Plaisted said. “And we extend the same quality the medical device market demands to all industries we serve.”
Virtually always located in a cleanroom environment, sputtering tools precisely deposit thin films of various materials, metals and/or dielectrics onto a substrate.
Next, the wafers typically enter etching or patterning equipment. Depending on the application, the substrate can return to the sputtering system several times during the manufacturing process to add different layers.
“Recipe management is critical throughout this process,” said Marc Fregeau, software development manager, KDF. “We develop all the programming for our customers – and update the software for them as their processes change.”
As more companies embrace contract fabrication, recipe control and monitoring has become increasingly important. In this emerging business model, a manufacturer provides fabrication services for a wide range of customers – each requiring different processes.
In 2010, KDF adopted a Rockwell Automation® control and information platform for their equipment featuring an Allen-Bradley® CompactLogix™ controller and an RSView®32 HMI solution.
“The initial control solution met our requirements,” Fregeau explained. “But as our customers’ process requirements became more demanding, we needed a more robust visualization solution that could grow with us.”
To enhance system performance, the company recently migrated to a FactoryTalk® View Site Edition (SE) HMI platform. In addition, the company opted for a CompactLogix 5370 controller (L36ERM), which features faster processor speeds and supports up to 16 axes of integrated motion over an EtherNet/IP™ network.
“Moving from the 32-bit HMI to the 64-bit FactoryTalk View solution was key,” Fregeau explained. “It provides a framework for an easy-to-use recipe management system – and the capacity to meet the demand for real-time information in a complex process environment.”
KDF systems are designed to monitor all process parameters including power supply voltages, sputter gas pressures/ratios, residual gas analyzer (RGA) background species vacuum integrity checks, substrate temperatures and more. The FactoryTalk View application helps enable real-time operator monitoring of those parameters through intuitive displays – and provides an audit trail of operator and alarm information in a centralized log database for absolute process validation.
“If there’s a process anomaly, the data logging helps determine the root cause,” Fregeau said. “The system also allows us to actively take ‘snapshots’ of the process in real time for reporting purposes.”
As an option, KDF customers can add FactoryTalk Historian to their system. FactoryTalk Historian features built-in connectivity to FactoryTalk View and provides robust, high-speed data collection and analysis capabilities.
For efficient system development, KDF applies the same Rockwell Automation control and visualization platform across its complete machine portfolio.
“Our sputtering tools share many components – as well as the control system,” Plaisted said. “A shared platform allows us to develop versatile equipment very cost-effectively.”
Looking toward the future, KDF is positioned to respond to fluctuating customer requirements – and an unpredictable marketplace.
“We are constantly changing,” Plaisted said. “And the Rockwell Automation control environment allows us to configure our tools and make changes as we need them.”
You have been identified in our equipment database as being a KDF “T”, “GT”, “NT” or early “i” sputter system owner who is still using either the obsolete Brooks Techware controller and/or the obsolete MKS 146 gauge package.
Most recently Microsoft has announced as well that its support of the Windows XP operating system has ceased, leaving owners of such vulnerable to both malicious and damaging interruptions. The KDF equipment still using these items can now be 30yrs.old. In regards to the Techware controllers Brooks support both from themselves and through their designated second and third parties ended almost 15 yrs. ago. Replacement hardware availability is now non-existent.
MKS had also announced many years back the end of the popular 146 vacuum gauge controller, due to component obsolescence. MKS support for the gauges which was limited to stock of these obsolete components ended this year. (The 146 was used extensively on GT and NT systems) To that extent KDF has developed and produced a 146-gauge replacement package that is available to customers who are already running on the KDF “i” controller platform or to customers needing the full upgrade. The package includes the MKS series of “Smart” gauging coupled with a VAT throttling gate valve. T and GT system owners already face additional obsolescence with the SX and MKS 287 & 290 controllers as well as NT users who are now also experiencing PC hardware obsolescence. Once upgraded to the “i” series the system can be further enhanced with options and upgrades to improve reliability and performance. Some of the available upgrades include a CPU, Windows 7 replacement kit, a load lock linear positional transducer, zeta scan velocity profiling controller, enhanced power supplies and new load lock heat pallet temperature measurement and control feature utilizing an optical sensor.
Customers that have already upgraded to the KDF “i” controller have insured themselves against further component obsolescence and unplanned down time. All upgraded systems operate on the same platform as the new KDF “i” systems (Windows 7) thus insuring years of compatibility and ongoing enhancements. All upgraded systems now have on line system available remote help from KDF.
For GT and NT system owners the system can be upgraded in the field typically within a week thus minimizing system down time and bringing your upgraded system back on line quickly. “T” systems typically take longer based upon the system’s configuration and are returned to the factory for full blown upgrading and reconditioning. In the past 10 yrs. KDF has successfully upgraded numerous systems both in the U.S., Europe, and the Pacific Rim. All upgrades include KDF’s ESP online Internet support Webex) See individual cut sheets for system type upgrade pricing.
Prudently planning a conversion now to the updated platform will minimize a lengthy unplanned tool down situation. (12-16 weeks)
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As always please don’t hesitate to contact KDF for a quote or for any other of your service or system needs.
Jac P Gnirrep Director of Customer Satisfaction jac@kdf.com
KDF acquired the MRC batch product line in 1986 and to that extent we have been supporting and maintaining those customers whose chose to continue with this product line for the last thirty plus years.
The support consisted not only of service, repairs and part sales but also selling factory reconditioned MRC tools which KDF supported and kept under warranty. KDF also maintained a vast inventory of spare parts to support this generation of equipment as well as a working service support system on the factory floor.
For those customers that were MRC users over the years many have migrated to the KDF line which allowed for a seamless transition of enhanced compatibility and familiarity both in vertical and horizontal sputtering. For those customers who have migrated to the family of KDF sputtering systems KDF ‘s roadmap and policy of “no tool left behind” has allowed for them to upgrade their systems over the years as the technologies and components utilized in the tools has evolved or gone obsolete.
For MRC users the end of life for these tools has approached the event horizon.
One of the benefits of crossing over is that it allows for the customer to take advantage of KDF’s complete applications lab that can assist you with transferring process requirements from MRC to KDF and can be done prior to delivery of your new equipment thus insuring minimum start up time.
By migrating to the KDF line of tools many consumable parts that you may have significant inventories of may be able to be utilized on the equipment such as cathodes, targets and shied sets. This alone offers a cost advantage over another competitor’s tool.
Trade in credit is also available for certain MRC systems. Contact Todd in Sales for more information. Todd@kdf.com 201-784- 5005.
Prudently planning a conversion or trading in your old tool now to the KDF equipment line will minimize a lengthy unplanned tool down situation.
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As always please don’t hesitate to contact KDF for a quote or for any other of your service or system needs.
Jac P Gnirrep Director of Customer Satisfaction jac@kdf.com
KDF was founded in 1986 however it was really born in 1957 with the beginning of Materials Research Corporation, which became a world leader in vacuum processing technology.
As often happens in the cycle of Industry there are births and rebirths with a new enterprise formed from the elements of a past Firm, KDF is one of these. KDF was created during one of the now too common downturns in the Semiconductor industry when the equipment companies discarded anything not perceived as mainstream front-end chip related. Materials Research Corporation, MRC, like others started leaving behind these other applications in pursuit of being the DRAM and CPU ‘Top Gun’ equipment supplier. KDF has, from that beginning, focused on servicing the customer in all aspects from custom integration and system design to individual maintenance planning. KDF has not left behind the semiconductor industry; we have taken the position of not leaving any application that we are capable of supporting and supporting well, behind.
As the large front-end semiconductor companies moved on in their almost single-minded pursuit a vacuum was left behind where customers wanted a ‘technology leader’ or ‘best of breed’ sputtering system but they weren’t necessarily coating silicon wafers. They may have been able to utilize the new cluster tool generation of systems coming out and even if sub-micron high-aspect via filling wasn’t on the wish list the stupendous cost of the systems was simply overwhelming and could not keep them in a competitive position. Here is where KDF has moved in and established a position as a leading provider of small and large area multi cathode inline sputtering systems that are evolved from a world standard MRC design. These systems were the first commercially manufactured semiconductor sputtering system with an installed base that grew to over 3,000 systems worldwide and is still growing today.
KDF today is a system provider to a large and diverse customer base covering a wide range of markets and applications.
Here are some examples; DWDM components, laser diode mirrors, digital micro mirrors, replicated diffraction gratings, Super lattice structures, X-Ray Mirrors, super-bright LEDs, ring laser gyroscopes, high power solid state lasers, large area digital X-Ray detector plates, OLED displays, TFT displays, pace maker components, PZT sensors & actuators, Si , GaAs, Ge and other (all) compound semiconductor devices, micro switches, photo masks, reticules, SAW & BAW devices, hybrids and resistor products, superconductor filters, photovoltaic, MCP night vision optics, MEMS-microsystems-nanotechnology, DNA and other medical sensors, thin film magnetic read write heads, HDI & MCM, multilayer nanocomposites, optical fiber coatings, and more.
KDF is a small company comprised of less than 50 individuals but one that has over 500 person years of experience in-house today and a heritage that goes back to 1957 with thousands of system delivered, hundreds of ‘specials’, dozens of designs and a few truly unique systems.
We at KDF strive to maintain integrity with our customers through our systems and our support as a partner.
954i Sputtering Systems Proven Leaders In Medical Device Production
Feb. 11, 2010–KDF today announced that a leading industry supplier has selected two of its 954i in-line sputtering system for use in manufacturing pacemaker components. The order verifies that KDF’s technology platforms continues to meet rigorous standards for producing advanced medical devices.
The 954i for its ability to create dense adherant coatings, a crucial aspect of medical manufacturing since each device is expected to perform flawlessly. The KDF 954i features Inset(TM) style cathodes, a cathode design that provides long lifetime and high utilization for thick coatings, like those that are used to protect critical pacemaker components. There is no margin for error in pacemaker manufacturing applications and KDF’s superior coating technology meets these standards.
As a new customer of KDF critical evaluations had to be met on performance of he 954i provides the process integrity required for producing high stakes medical devices like pacemakers,” said Todd Plaisted, director of marketing. “KDF already maintains a presence in the medical devices market and this order has continued our market penetration for this industry.”
KDF offers advanced and reliable batch in-line sputtering systems at the industry’s lowest cost of ownership. These systems are used around the world in the semiconductor, telecommunications, aerospace and medical technology markets, each tailored to meet specific processing needs.
For the this process KDF configured the 900 Series system with a newly developed phased dual cathode sputter capability for higher throughput while achieving greater target material utilization. With sputter down capability and easy substrate loading, the 954i is ideally suited for medical applications which produce uniform films with an exacting, but repeatable, high-throughput process.
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About KDF
KDF Electronic & Vacuum Services, Inc., produces batch in-line sputtering tools in a wide variety of R&D and production formats for the mainstream silicon, emerging materials and flat-panel display markets. KDF systems are used in the production of semiconductors, photomasks, telecommunications networks, wireless circuits, gallium arsenide (GaAs), high density interconnect, sensors, optoelectronics, flat panel display and radio frequency power devices. KDF is located in Rockleigh, New Jersey, and has representatives in Europe, Japan, Taiwan, Singapore, Malaysia, China and Korea.
Company Contacts
Kurt Flechsig
President & CEO
Tel: +1 (201) 784-5005
E-mail: kurt@kdf.com
