journal article·2022-01-21Open access

Accelerated Testing and Reliability of FDM-Based Structural Electronics

Bartłomiej Wałpuski, Marcin Słoma

Applied Sciences· Volume 12· Issue 3

Abstract

With the development of the miniaturization of electronic systems, heat dissipation from components has become an increasing challenge. Structural electronics represent a new approach to this problem. Instead of downsizing all the elements, in this idea, electronic parts of the device are embedded into its mechanical construction. This approach has many advantages, but the reliability of systems constructed this way has not been extensively studied so far. In this work, circuits consisting of silver ink conductive traces were printed on FDM polymer substrates, with or without 0 Ω resistors, and were subjected to accelerated aging testing. The samples were divided into three groups, and for each of them, the mean time to failure was calculated, which for the best group was 8000 h. This paper also presents the mechanism that led to the failure of these systems, as well as actions that will lead to the elimination of this phenomenon.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Additive Manufacturing and 3D Printing Technologies · Advancements in Semiconductor Devices and Circuit Design · Electronic Packaging and Soldering Technologies

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

Affiliations

Micro- and Nano-Technology Division, Institute of Metrology and Biomedical Engineering, Faculty of Mechatronics, Warsaw University of Technology, 8 Boboli St., 02-525 Warsaw, Poland

Funding

Foundation for Polish Science

References (35)

Show source-provided references
1. Printed electronics: The challenges involved in printing devices, interconnects, and contacts based on inorganic materials10.1039/c0jm00264j ↗
2. Self-healing soft electronics10.1038/s41928-019-0235-0 ↗
3. Electronics for the human body10.1001/jama.2014.17915 ↗
4. Invisible electronics: Metastable Cu-vacancies chain defects for highly conductive p-type transparent oxide10.1016/j.apmt.2017.07.004 ↗
5. Integrating stereolithography and direct print technologies for 3D structural electronics fabrication10.1108/13552541211212113 ↗
6. 3D Printing multifunctionality: Structures with electronics10.1007/s00170-014-5717-7 ↗
7. Plastics Get Flexible for Electronics10.1002/j.1941-9635.2016.tb01473.x ↗
8. Transistors versus Vacuum Tubes10.1109/JRPROC.1956.274926 ↗
9. Reliability of Power Electronic Systems10.1109/MIE.2018.2825481 ↗
10. Arsenault, J.E., and Roberts, J.A. (1980). Reliability and Maintainability of Electronic Systems, Pitman Publishing.
11. Improving the Reliability and Safety of Automotive Electronics10.1109/40.210523 ↗
12. Condition monitoring for device reliability in power electronic converters: A review10.1109/TPEL.2010.2049377 ↗
13. Baylakoglu, I., and Hedin, E. (2011). PCB Delamination. The ELFNET Book on Failure Mechanisms, Testing Methods, and Quality Issues of Lead-Free Solder Interconnects, Springer.10.1007/978-0-85729-236-0_12 ↗
14. Vicenzo, A. (2011). Tin Whiskers. The ELFNET Book on Failure Mechanisms, Testing Methods, and Quality Issues of Lead-Free Solder Interconnects, Springer.10.1007/978-0-85729-236-0_6 ↗
15. Dušek, K., Bušek, D., and Veselý, P. (2021). Overview of Selected Issues Related to Soldering. Welding—Modern Topics, IntechOpen.10.5772/intechopen.91023 ↗
16. Hermans, M.J.M., and Biglari, M.H. (2011). Void Formation by Kirkendall Effect in Solder Joints. The ELFNET Book on Failure Mechanisms, Testing Methods, and Quality Issues of Lead-Free Solder Interconnects, Springer.10.1007/978-0-85729-236-0_5 ↗
17. Maqsood, N., and Rimašauskas, M. (2021). Delamination observation occurred during the flexural bending in additively manufactured PLA-short carbon fiber filament reinforced with continuous carbon fiber composite. Results Eng., 11.10.1016/j.rineng.2021.100246 ↗
18. Effect of build orientation on the mechanical reliability of 3D printed ABS10.1108/RPJ-09-2015-0122 ↗
19. Calculating Reliability using FIT & MTTF: Arrhenius HTOL Model
20. A review on the fused deposition modeling (FDM) 3D printing: Filament processing, materials, and printing parameters10.1515/eng-2021-0063 ↗
21. Additive manufacturing (3D printing): A review of materials, methods, applications and challenges10.1016/j.compositesb.2018.02.012 ↗
22. Extrusion bioprinting of soft materials: An emerging technique for biological model fabrication10.1063/1.5059393 ↗
23. Jianping, L., and Guiling, D. (2004, January 3). Technology Development and Basic Theory Study of Fluid Dispensing—A Review. Proceedings of the Sixth IEEE CPMT Conference on High Density Microsystem Design and Packaging and Component Failure Analysis (HDP ’04), Shanghai, China.
24. 3D bioprinting for engineering complex tissues10.1016/j.biotechadv.2015.12.011 ↗
25. Bayle, F., and Mettas, A. (2010, January 25–28). Temperature Acceleration Models in Reliability Predictions: Justification & Improvements. Proceedings of the Annual Reliability and Maintainability Symposium, San Jose, CA, USA.10.1109/RAMS.2010.5448028 ↗
26. Criteria for the assessment of reliability models10.1109/96.618221 ↗
27. Lakshminarayanan, V., and Sriraam, N. (2014, January 6–7). The Effect of Temperature on the Reliability of Electronic Components. Proceedings of the IEEE CONECCT 2014—2014 IEEE International Conference on Electronics, Computing and Communication Technologies, Bangalore, India.10.1109/CONECCT.2014.6740182 ↗
28. An Infant Mortality and Long-Term Failure Rate Model for Electronic Equipment10.1002/j.1538-7305.1985.tb00418.x ↗
29. Transitioning to physics-of-failure as a reliability driver in power electronics10.1109/JESTPE.2013.2290282 ↗
30. Copper Nanoparticles for Printed Electronics: Routes Towards Achieving Oxidation Stability10.3390/ma3094626 ↗
31. Nanoscale joule heating and electromigration enhanced ripening of silver nanowire contacts10.1021/nn4065567 ↗
32. Electromigration experiments by spark plasma sintering in the silver-zinc system10.1016/j.jallcom.2015.02.122 ↗
33. Low temperature coefficient of resistivity Ag-Cd and Ag-Sn alloys—Structure and transport10.1016/j.mseb.2003.10.012 ↗
34. Resistivity measurements of layered metallic films at various microwave frequencies and temperatures using the micro-strip T-junction method10.1088/0957-0233/13/7/322 ↗
35. Degradation mechanism of Ag-epoxy conductive adhesive/Sn-Pb plating interface by heat exposure10.1007/s11664-002-0124-5 ↗