Flexible electronics provide new design options not afforded by rigid electronics in a variety of applications including wearable electronics, robotics and automotive systems. However, the processes for the manufacturing of complex electronic assemblies using fine-pitch components are not as well developed as those for rigid electronics. The lack of structural rigidity of flexible printed circuit cards requires attention to assembly configuration for double-sided flexible assemblies. In addition, mechanisms are needed to compensate for the deformation and warpage of the flexible substrate and components during assembly. In this paper, the stresses in solder joints of double-sided flexible assemblies have been measured during thermal excursions using x-ray micro-computed tomography in conjunction with digital volume correlation. The method allows for non-invasive measurement and does not require cross-sectioning of the part for the purpose of deformation and strain measurement. In addition, the measurements are not limited to the joints in the line of sight. The three-dimensional measurements of deformation and strain have been visualized on the geometry of the solder joints in the package. Digital volume correlation (DVC) method has been used to find the displacements and strains in interconnects of operational electronics. The x-ray microscopic computed tomography (μCT) system has been used to generate the 16 bit digital volume data. The x-ray detector has ability to image the x-ray attenuation of x-rays through the object. Reliability testing of SAC 305 solder interconnects has been performed on double-sided flexible circuit board using x-ray μCT by heating the package to 100°C. The flexible circuit board used in this experiment is of BGA 256-144 combination, two packages, A-PBGA256-1.0mm-17mm and A-CABGA144-1.0mm-13mm.

A 3D printed fixture has also been used to support the flexible board and keep it flat while in the CT scan machine. The reference and deformed scans are then re-constructed 3D using Volume Graphics, and Digital Volume Correlation performed using MATLAB modules. Reliability of double-sided flexible printed circuit boards will be discussed and any crack, defects, or deformation in the solder interconnectivity which might occur while heating the package on flexible board is presented. The solder joint strains during thermal excursions are also compared between the flexible and rigid printed circuit assemblies.

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