Taking a look at how Boston Engineering helped an industrial brand accelerate semiconductor production.
The semiconductor industry demands cutting-edge technology to enhance precision and efficiency. When an industrial brand sought to develop an advanced printed circuit board (PCB) controller for its solid-state RF plasma generator, it turned to Boston Engineering for expert engineering solutions. The challenge was to create a high-performance control system capable of managing complex plasma generation processes for early adopters in semiconductor manufacturing.
The focus and discipline of DFX is a powerful tool if used as part of a broader strategic approach to developing product/process differentiation, and a sustainable advantage against competition. Involve Design for X in Strategy. Once your team has determined the focus of your strategy, place the focus of design on developing competitive advantage.
At Boston Engineering, DFX is a core part of creating values during our product development process. We focus on several key DFX areas that align with our expertise:
- Design for Manufacturability (DFM)
- Design for Assembly (DFA)
- Design for Cost (DFC)
- Design for Testability (DFT)
- Design for Reliability (DFR)
- Design for Serviceability/Maintainability (DFS)
- Design for Usability (DFU)
- Design for Modularity (DFMo)
Learn more about Design for X (DFX) at Boston engineering: Boston Engineering Design for X
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The Challenge: Engineering a High-Performance PCB Controller
The client was developing advanced solid-state plasma generators designed to support semiconductor processing applications. To succeed, they required a highly specialized PCB controller for their 3kW solid-state generator—a critical component for plasma generation. The challenge was to develop an integrated subsystem that could meet the demanding power and control requirements of multi-unit plasma generation systems.
Boston Engineering took on the responsibility of developing this advanced PCB controller, ensuring seamless integration of embedded, electrical, and software engineering to optimize performance.
Boston Engineering’s Approach: A Full-System Development Strategy
Boston Engineering managed the entire engineering process, from planning and specification to verification and implementation. Their approach combined high-performance hardware, advanced software frameworks, and precise power management to meet the stringent requirements of semiconductor plasma processing.
Key aspects of the engineering strategy included:
- Embedded system development, integrating hardware and software seamlessly.
- Electrical engineering expertise, ensuring efficient power management and precision.
- Software development with Linux, optimizing performance and flexibility.
- Simulink Embedded Coder for traceability and system transfer, ensuring a smooth transition to manufacturing.
- High-performance data conversion, featuring:
- 24-channel digital-to-analog converters (DAC) for precise signal output.
- 64-channel analog-to-digital converters (ADC) for accurate data collection and control.
Interested in providing your product development team with DFX skills? Learn More about our Applied DFX process and development workshops.
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The Impact: Advanced Power Management & Performance Optimization
By leveraging its engineering expertise, Boston Engineering delivered a highly capable PCB controller that significantly enhanced plasma generation capabilities in semiconductor processing. The impact included:
- Efficient power distribution: Enabled four plasma generators to operate concurrently.
- Optimized performance: Improved power measurement and management for enhanced plasma generation efficiency.
- Simplified complexity: Effectively handled multi-unit requirements, ensuring seamless integration and operation.
Powering the Future of Semiconductor Manufacturing
By developing a high-performance PCB controller for the client's solid-state RF plasma generator, Boston Engineering played a crucial role in advancing semiconductor processing technology. Our expertise in embedded systems, software development, and power management helped accelerate innovation while ensuring precision, reliability, and scalability.
For companies looking to enhance power management and control systems in semiconductor applications, Boston Engineering delivers cutting-edge solutions tailored to industry demands.
Looking to optimize your engineering systems?
Contact Boston Engineering today to explore how we can help accelerate your next semiconductor innovation.
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Developing successful new products from scratch is challenging enough, but what about improving on existing designs?
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Understanding the Importance of a DFX approach
Applying Design for X (DFX) methodologies upfront in product development optimizes the entire lifecycle by improving manufacturability, testability, reliability, usability, and other critical characteristics. This avoids costly redesigns later on, facilitates high-quality products that satisfy customers, reduces manufacturing and service costs, and supports flexibility through modularity and platforms. The holistic perspective of DFX drives efficient, cost-effective delivery of successful products that provide competitive advantage. Investing in DFX early pays dividends across the entire product lifespan.
Do you offer training on DFX for engineering teams?
Education is critical to effectively implement DFX principles. We provide training tailored to your engineers’ roles and product lines. This includes overall DFX methodology, deep dives into specific disciplines like design for reliability or manufacturability, and practical application workshops. Our hands-on approach combines real-world examples and case studies with tutorials on leading DFX software tools. The goal is building organizational DFX expertise and establishing repeatable processes that endure beyond individual projects. Investing in DFX knowledge pays dividends across your entire product portfolio.
Ready to Begin your next DFX Project?
Whether you’ve created a new technology, or have an innovative way to use an existing solution, Boston Engineering will turn your ideas into reality. Our experts and Industry Partners will enhance your current team or manage the entire Product Development Process from Market Analysis to Production. Don't leave complex projects or high visibility product launches to chance. Know you're going to get the results you want by working with industry leaders in design, development, and deployment of innovative products driven by Novel Engineering. Contact Boston Engineering Today to get started.
No matter the challenge, our team possesses the expertise in the engineering disciplines and technologies you need to bring your vision to life. Impossible Challenge? Try Us.
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Impossible Challenge? Try Us.
Selecting a partner to help you complete your design project is a valuable option to reduce project duration and save money.
The Boston Engineering product development system encompasses DFX to ensure a smooth product launch and success in the marketplace. Boston Engineering has DFX knowledge and experience to address aspects and values of a product such as manufacturability, test, reliability, safety, serviceability, cost, and compliance with industry standards and government regulations.
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