Manufacturing Capabilities
FRALOCK combines over fifty years of experience in composite materials and manufacturing expertise to provide value-added solutions to some of the world’s most technically advanced OEM’s. We design and manufacture polymer, foil, ceramic, and adhesive-based products using thin, flexible materials and custom composites through a global supply chain.
We are an ISO9001:2015, AS9100:D, ISO13485:2016 certified, and FDA registered company dedicated to providing exceptional customer service, product realization, custom manufacturing solutions, and automated placement systems for the most demanding requirements. Fralock specializes in engineered solutions, providing components and subassemblies that are guaranteed to work in your application.
Our engineering team is able to quickly understand your performance needs and can often make suggestions that improve the reliability and performance of your products. In many instances, Fralock becomes a virtual extension of our customers’ engineering departments.
- Adhesiveless Lamination Technology (ALT)
Fralock utilizes a unique pioneered polyimide lamination process, Adhesiveless Lamination Technology (ALT) that eliminates the use of adhesives. Adhesiveless laminates provide high temperature resistance, dimensional stability, low outgassing, durability, and solvent resistance. Traditional polyimide laminates are notoriously unreliable at temperatures that exceed the Glass Transition (Tg) of the adhesives used in their construction.
Polyimide is closely matched to the CTE of copper, and can also be used to bond many other metals with bond strengths typically > 10 pli. If your application requires high temperature resistance, dimensional stability, low outgassing, durability, and solvent resistance, adhesiveless laminate technology is the solution.
- Flex/Rigid-Flex Circuits
- Liquid Soldermask Thickness 25um (1mil)
- Photo Imageable Coverlay Min 25um (1mil)
- RoHS & Non RoHS PCB/Flex Circuit Manufacturing
- Automated Optical Inspection (AOI)
- Electrical Testing (Open/Shorts, Function, and Hi-Pot)
- Ability to Test for 10-15 Resistance Leakage
- Trace / Space 37um (1.5 mil)
- Micro / Vias Min 50u (2 mil)
- Blind/Buried Vias (2mil)
- Via Fill (conductive and non-conductive)
- Laser- Precision Drilling / Excising<50um (2mil)
- Layer Count Capability 1-10+
- Unsupported Traces / Cantilever Leads
- Surface Mount Technology (SMT) and thru-hole assembly services
- Controlled Impedance Design and Testing
- Electronics Assembly
We provide the following assembly processes for your Flex and Rigid-Flex requirements:
- 3 SMT Lines
- Automated Solder Paste Printer
- Pick-and-Place
- Convection Oven Reflow
- In-Line Cleaning
- Real Time X-ray
- Post-Assembly Electrical Test
- 3D AOI (Automated Optical Inspection)
- Wave Solder (Leaded & Lead Free)
- Selective Soldering Machine With Preheat Oven
- Conformal Coating, Underfill, And Potting Solutions
- Underfilling Encapsulation – protects in flip-chip packaging, reduces stress on solder bumps of chips, and protects against moisture, ionic contaminants, thermal vibration and shock.
- Potting Materials – Protects the electronic assembly against vibration/shock, corrosion, and chemicals. Also provides electrical insulation, enhanced mechanical strength and heat dissipation.
- Injection Molding (LCP & ABS plastics)
- Pantone Color Matching
- Textured Finishes
- Resin Selection
- Surface Finishing
Coating the copper on your Flex and Rigid-Flex PCB is essential to protect it from oxidation and deterioration. We provide several types of surface finishes to fit your needs.
- Selective Plating on Copper Nickel and Gold
- Soft Electrolytic Gold (Wire Bondable)
- ENIG (Electroless Nickel/Immersion Gold)
- ENEPIG (Electroless Nickel/Electroless Palladium/Immersion Gold)
- Hard Gold – Knoop 200+
- Tin/Lead (No Fusing)
- Immersion Tin
- HASL (Hot Air Solder Leveling) and Lead-Free HASL
- Large Format Plotting
Fralock provides specialized imaging technology that allows greater precision at extremely large scales.
Extremely long flat flex etched foil cables (hundreds of feet) can be produced.
- Resolutions from 4,000 to 16,000 DPI
- Large Scale; 48” width max, Length 20+ feet
- Feature size to 12.5 micron
- Film Masks;7 mil Mylar, Silver Halide emulsion
- Plastics; Epoxy/Glass, Pyralux, Kapton, Polyimide, Ceramic, Teflon, Noryl, PEN, Cirlex, etc.
- Thickness Range; .001” to .375” thick
- Metal Cladding; Copper, Monel, Nickel, NiChrome, Stainless Steel; 1 micron to 5 mil thick
- Bond; Adhesiveless, NiChrome sputter tie coat, or conventional adhesive bonded
- Ceramic Processing
- Plating, Lapping, Dicing and Brazing services
- Heater Cooler Assemblies
- Laser welding for high temperature lead attach
- Isostatic Pressing
- Pre-fired CNC machining tolerances +/- 1%
- Post fired dicing to +/- .001”
- Post Fired lapping/polishing to sub-micron flatness for parts up to 50mm square
- Electroless Ni and Au plating
- Metallizing and brazing of AlN heaters
- Thin film coatings for ESD control or fine surface lines and spaces to 12um (.0005”)
- Multi-zone Control systems with internal tungsten RTD, thermocouple or platinum RTD feedback capability
- RoHS & REACH Compliant
- UV and CO₂ Laser cutting
CNC Milling: Fralock provides custom CNC cutting service that includes CNC milling, drilling, and routing. Our in house capabilities allow us to hold critical tolerances on flatness, true hole position and parallelism. Whether it’s a prototype or large quantities, we can insure no warping or bowing of your parts. We can offer quick turn-around and tight tolerances, with production quality.
- Die Cutting
- Rotary
- Flatbed
- Steel Rule – Short Run Flexibility
- Class “A”
- UV and CO2 Laser Cutting
- Complex multi-layer island place die-cutting
- CAD cutting, plotting, prototyping
- Laser cutting
- Flatbed or Progressive die-cutting
- Steel rule dies
- Multi-layer die-cutting
- In-line optical registration die-cutting
- Zoned adhesive or dead-end areas
- Die-cuts for automation/pick-and-place dispensing
- Liner swapping, split liners, extended tabs
- (Ceramic Lamination from Oasis, also other capabilities like the stainless steel and glass lamination? Dielectric - temps up to 450 C)
- Diamond Machining of Ceramics or Glass to Tight Tolerance
- Ultra-Thin flexible zirconia substrates manufacturing
- Ceramic Processing - Plating, Lapping, Dicing and Brazing
- Thin Film Circuits – Ceramic substrates
- Micro Cooling channels - Internal and External Channels in Aluminum Nitride
- Cold Isostatic Pressing of Ceramic Powders to Near Net Shape
- Adhesive Coating
Fralock offers many adhesive coating methods to provide a solution designed specifically for your application.
Custom adhesives can be provided in tape, sheet, or precision die cut form.
- Hot-melt adhesives
- Thermoplastic adhesives
- Dry edge capable
- Slot or pattern coating”
- Zone Coating
- Adhesive Products
- Single coated adhesive tapes
- Double-coated (supported) adhesive tapes
- Foamed adhesive tapes
- Heat activated adhesive tapes
- Custom widths, sheets, or precision die cut
- Precision Slitting
- Pull – Through
- Re-Roll
- Bologna Style
- Micro Slitting from .015”
- Custom widths
- Clean Room Processing and Packing
