3D Digital Stitching Imagery is Revolutionizing Failure Analysis and Product Analysis

Steve Greathouse
Plexus Corp.
Nampa, ID, USA

We live in a three dimensional world, so why has the serious exploration of the many options of generating real and pseudo 3D imagery taken until the last decade to happen? This presentation will outline the different types of 3D imagery and how they have found uses in various applications. There are several different companies making 3D vertical stitching equipment and this will show how this capability is being used in the medical, industrial, and especially the electronics industries. The presentation will include various short videos and several images of electronic components that are impossible to get without 3D stitching capability. This includes several examples of how 3D microscope system has saved 100's of thousands of dollars by catching problems and proving to the vendors that they were shipping out of spec parts. Nothing shows the problems better than a crystal clear image with measurements of the defective parts. (Remember, "He that has the best data and clear photos wins any argument").

A method of incorporating moving GIF images to find hard to see defects will be demonstrated. A short discussion on the calibration method of the 3D imaging system, the Gage R&R and accuracy studies, and the 3D rotational imaging capabilities of the system will be shown. An example of using video capture capability to show dendrite growth on components and boards will be demonstrated.

3D imagery has brought significant changes to the human culture and have significant advantages over 2D images. 3D has enhanced the reality of the objects around us and enabled us to relate to them as being real and tangible.

3D has assisted us to see images that would be impossible to capture and publish in any other way.

3D videos are helping to show actual moving phenomena that show us the small details and movements in the images we are viewing.

As new technologies continue to shrink our products in the manufacturing world, the techniques we use to examine the parts, understand their construction, and detect their failures will need to evolve to see and inspect these parts. Failure Analysis techniques will migrate to more 3D detection including optical recording, acoustic 3D rendering, and 3D X-ray systems. All these techniques combined will give us a more complete understanding of the problems that face these new products.