Designed entirely from the ground up, this automated wafer lamination platform transfers pressure-sensitive adhesive (PSA) films onto semiconductor wafers through a fully automated roll-to-roll lamination process. The system integrates robotic handling, precision motion control, cleanroom engineering, and a proprietary lamination engine into a single production-ready platform.
Designed entirely from the ground up, this automated wafer lamination platform transfers pressure-sensitive adhesive (PSA) films onto semiconductor wafers through a fully automated roll-to-roll lamination process. The system integrates robotic handling, precision motion control, cleanroom engineering, and a proprietary lamination engine into a single production-ready platform.
At the heart of the system is a completely custom lamination engine developed by Protoform. Unlike conventional roll-to-roll laminators designed for continuous web processing, this machine employs a unique start-stop lamination process that applies adhesive to one wafer at a time. The system accommodates material widths ranging from 50 mm to 250 mm while maintaining precise control of alignment, tension, and process repeatability. To my knowledge, this represented the first machine of its kind developed specifically for discrete wafer lamination rather than continuous web processing.
At the heart of the system is a completely custom lamination engine developed by Protoform. Unlike conventional roll-to-roll laminators designed for continuous web processing, this machine employs a unique start-stop lamination process that applies adhesive to one wafer at a time. The system accommodates material widths ranging from 50 mm to 250 mm while maintaining precise control of alignment, tension, and process repeatability. To my knowledge, this represented the first machine of its kind developed specifically for discrete wafer lamination rather than continuous web processing.
This project required the integration of industrial robotics, precision motion systems, pneumatic controls, roll handling, cleanroom design, vacuum workholding, machine safety, and custom mechanism development into a cohesive automated manufacturing platform. It represents a complete machine architecture developed from concept through production-ready design, demonstrating Protoform's ability to solve complex manufacturing challenges where no commercial solution exists.
Protoform Design is best suited for companies facing a meaningful mechanical or manufacturing problem that requires experience, independent thinking, and direct technical ownership. The service is positioned as professional engineering expertise rather than commodity CAD labor, temporary staffing, or low-cost production work.