IntElect supports semiconductor wafer frame manufacturing

Located in Croatia, Meliori Polymer Engineering is currently the only company to manufacture, clean, ship and refurbish polymeric semiconductor support frames in Europe. Given the high demands for cleanability and repeatability, two Sumitomo (SHI) Demag IntElect injection moulding machines were installed to manufacture the wafer frames.

Alongside the injection moulding cells, the facility is equipped with a fully automated CNC machine specifically designed to remove burrs from the eight-inch frames. To maintain the stringent cleanliness standards required for semiconductor support frames, the site also features an automated washing and drying cell. 

Additionally, a dedicated ISO Class 6 packaging cleanroom has been established, providing the controlled environment essential for contamination-free packaging. The cleanroom has been thoughtfully designed with capacity for future growth, allowing for the addition of two further production lines as demand for semiconductor structural frames increases. 

Frame stability is especially important for the chip manufacturing process. Without the stability of the semiconductor wafer, chips just simply would not exist. The process involves a polymer film being glued to a single polymer wafer support, onto which a disk with chips is then glued. There can be 1,000 to 10,000 of them, depending on the size and technology. The cutting process then requires meticulous stability, as the chips are mechanically hard, yet each thinner than a single hair strand.

Spotting venture potential

Like many formative companies and despite the promising market opportunities, Meliori struggled to generate interest from many of the big moulding machine suppliers. "The biggest motivation for us was working with a local supplier who was genuinely interested in bringing our idea to life. Matjaž Kos from Top Teh invested the time and energy, presenting us with options for a complete production line. This included the all-electric moulding machine from Sumitomo (SHI) Demag," recalled company founder Marko Omazić. 

The installation of a standard IntElect injection moulding machine provided Meliori with an extensive range of features and consistent production repeatability, Kos stated. "It was a simple case of a quality machine delivering everything that Meliori needed to exceed the manufacturing precision, reliability and price per unit of current chip frames being imported into Europe from Asia." The team especially valued having direct access to the local integrator’s expertise in machine validation, process optimisation and training support.

Drawing on their extensive backgrounds in materials science and photovoltaic technology, the Omazićs carefully selected raw materials that would meet the mechanical property and tensile strength requirements for wafer frames. Each 8" wafer frame is moulded from a glass fibre and mineral filled polyphenylene sulphide compound. This enables Meliori to offer a unique refurbishment service.

"Rather than single use components that generates excess waste, we intentionally wanted to ensure that the frames were moulded from a robust material that could be returned to our facility. On arrival they are quality checked, refurbished, cleaned, repacked and shipped back to customers. This service is central to our sustainability journey and aqua-friendly manufacturing and cleaning process. Combined with the energy and efficiency savings gained from using the Sumitomo (SHI) Demag IntElect machines, the CO2 and waste management savings are huge," said Antonia Omazić. 

Made in the EU for semiconductor self sufficiency

As chip manufacturing can be resource intensive, the measures implemented by Meliori support the sustainability efforts of European semiconductor manufacturers. "By integrating renewable energy sources, using innovative materials, and embracing a circular economy approach, the European semiconductor industry can significantly enhance its sustainability credentials," she added. 

In localising the value chain, the quality of wafer frames can be tightly controlled. It also addresses recent geopolitical risks and supply chain challenges.

"The semiconductor market in Europe is evolving rapidly. Growing demand for advanced electronics, for example smartphones, laptops, electric vehicles, as well as AI, industrial robots, and healthcare is leading to a surge in demand for local infrastructures, R&D semiconductor hubs and manufacturing support. Enterprises like Meliori supported by local machinery manufacturers and integrators will play a critical role in building self-sufficiency and mobilising these opportunities," said Sumitomo (SHI) Demag chief sales officer Anatol Sattel.

The Ireland semiconductor market is especially large observes UK and Ireland MD  Dave Raine. Reliant on high performance electronic components and advanced AI capabilities, the Ireland semiconductor sector generates €15.5bn in annual revenue. "Projections indicate that the market will expand even further in the coming years. Yet Ireland continues to prioritise sustainability and energy efficiency. These factors should put Meliori in an extremely strong position," he noted.

By focusing exclusively on the European market, Meliori received a large preorder for wafer frames from one of Europe`s largest manufacturer of semiconductors. "Receiving the intent to order was the strongest vote of confidence in our product. Our long-term plan is to continue innovating and using our market knowledge to expand and diversify our product portfolio, as well as open our own R&D centre. Elevating our Made in the EU status," Antonia Omazić concluded.

For more information: 

sumitomo-shi-demag.co.uk  

sumitomo-shi-demag.ie