Electronics Guide

Printed Electronics Power

Enable additive manufacturing of electronic circuits and devices. Topics include inkjet printing power systems, screen printing power, gravure printing power, flexographic systems, slot die coating power, spray coating systems, sintering technologies including photonic sintering and plasma sintering, laser annealing systems, roll-to-roll power systems, web handling, tension control, registration systems, and quality control power.

Semiconductor Fabrication Power

Power systems supporting chip manufacturing including ion implanter power supplies, plasma etch power systems, sputter deposition power, chemical vapor deposition systems, molecular beam epitaxy power, electron beam and focused ion beam systems, photolithography power, wafer handling power, clean room power quality, process tool power distribution, facilities power systems, backup power, power monitoring, and energy recovery systems.

Process-Specific Requirements

Manufacturing processes impose unique demands on their power systems that often exceed typical industrial specifications. Semiconductor plasma etching requires RF power sources capable of delivering kilowatts at frequencies from hundreds of kilohertz to tens of megahertz with rapid power modulation for advanced process control. Ion implantation systems need high-voltage power supplies delivering hundreds of kilovolts with exceptional stability for precise dopant placement.

Chemical vapor deposition processes require precisely controlled power for substrate heating, plasma generation, and precursor delivery systems. Electron beam and laser systems demand pulsed or continuous power with microsecond-level response times. Each manufacturing technology presents distinct power supply challenges that drive specialized design approaches.

Power Quality and Stability

Manufacturing equipment sensitivity to power quality far exceeds that of typical industrial loads. Voltage sags lasting milliseconds can abort hours-long semiconductor processes, destroying product worth millions of dollars. Harmonic distortion affects precision positioning systems and measurement equipment. High-frequency noise couples into sensitive analog circuits and can corrupt digital communications.

Manufacturing facilities invest heavily in power conditioning infrastructure including uninterruptible power supplies, dynamic voltage restorers, active filters, and isolation transformers. Process tools incorporate their own power conditioning to further improve the quality of power delivered to sensitive subsystems. Power monitoring systems track quality metrics continuously to identify degradation before it impacts production.

Energy Efficiency and Recovery

Manufacturing facilities consume enormous amounts of electrical energy, making efficiency a critical concern for both operating costs and environmental sustainability. Semiconductor fabs may consume tens of megawatts continuously, with power costs representing a significant portion of manufacturing expenses. Improving power conversion efficiency even a few percentage points can save millions of dollars annually.

Energy recovery systems capture waste heat and regenerative energy from manufacturing processes. Heat exchangers recover thermal energy from process cooling systems for facility heating or absorption cooling. Regenerative drives return energy to the grid when motors decelerate. Advanced power architectures enable load sharing and peak demand reduction across facilities.

Facilities Power Distribution

Manufacturing facilities require sophisticated power distribution systems to deliver reliable power to process tools while maintaining isolation between sensitive equipment. Medium-voltage distribution at 4160V or higher feeds step-down transformers serving individual process bays or tools. Redundant feeders and automatic transfer switches ensure continuity during utility disturbances.

Clean power distribution for sensitive equipment uses dedicated transformers with electrostatic shields, isolated ground systems, and filtered power panels. Separation between clean and dirty power prevents coupling of noise from motors, drives, and other disturbing loads into sensitive process equipment.

Backup and Emergency Power

Critical manufacturing processes require backup power systems to prevent costly process interruptions and equipment damage during utility outages. Large uninterruptible power supply systems provide immediate backup for process tools, allowing controlled shutdown or ride-through of brief disturbances. Diesel generators supply extended backup power, with automatic transfer completing within seconds of detecting utility failure.

The backup power strategy must consider both the criticality of different loads and the cost of protection. Process tools in mid-cycle may require immediate backup to prevent product loss, while support systems can tolerate brief interruptions. Prioritized load shedding ensures critical processes receive power even when backup capacity is limited.

Power Monitoring and Management

Comprehensive power monitoring provides visibility into energy consumption, power quality, and system health throughout manufacturing facilities. Smart meters and power analyzers track consumption by area, process, and equipment, enabling accurate cost allocation and identifying efficiency improvement opportunities. Power quality monitors detect and record disturbances for root cause analysis.

Energy management systems optimize facility power consumption by coordinating equipment operation, managing demand peaks, and integrating renewable energy sources. Predictive analytics identify developing problems before they cause failures, while automated responses to power quality events minimize process impact.