1. When to use it
- Wire bond yield has dropped, or a defect keeps coming back: non-stick on pad or lead, lifted balls, pad cratering, wire sweep, shorts or weak stitch pull.
- You’re converting devices from gold to copper, or qualifying palladium-coated copper or silver wire, and need a process window that survives reliability testing.
- A new package or a new technology is moving from pre-production to full production.
- You’re introducing new bonders, upgrading hardware or software, or want one recipe to run the same on every machine.
- Your engineers and technicians need practical training in copper wire bonding.
This is consultancy on your own process. If you want an independent audit of a supplier’s wire bonding, see the wire-bond process audit guide and the VDA 6.3 process audit.
2. What we can help with
| Area | Typical work |
|---|---|
| Yield and defect troubleshooting | Defect Pareto and failure-analysis review, root cause on the floor, parameter and consumable checks, and a containment and correction plan |
| Copper and alternative wires | Gold-to-copper, PdCu and silver wire conversion: characterisation, DOE, process window, free air ball and intermetallic checks, and release to production |
| New package introduction | QFN and MLP, and small-outline packages such as SOT, SC70, TSOT, SSOP, TSSOP and MSOP: from first build to stable volume, with cycle time and yield targets |
| Bonders and recipe control | New bonder introduction, hardware and software upgrades, machine-to-machine portability calibration, and central recipe management so every bonder runs the released recipe |
| Equipment benchmarking | Structured evaluation of bonder platforms on your own devices before you buy |
| Training | Copper wire bonding for engineers and technicians, taught by a certified trainer |
3. How it runs
- BeforeData firstUnder NDA if you want one. You send yield and defect data, current recipes, pull and shear results, failure-analysis reports, and the control plan and FMEA for the line in scope.
- Day 1On the floorWalk the line with your engineers, watch the bonders run, and check the data against what is actually happening.
- Next daysRoot cause or DOEProve the cause with evidence, or run a designed experiment to find a robust process window.
- CloseHand-overAgreed actions with owners, recipe and control-plan changes, and what to monitor.
- AfterFollow-upRemote support while the changes settle, and a return visit if needed.
4. What you receive
- Findings and root-cause evidence, in writing
- DOE plan and results, and the recommended process window
- Proposed changes to recipes, the control plan and the FMEA
- An action list with owners and dates
- Training material, where training is part of the scope
5. Who does the work
Our wire bonding specialist, profile MY-02, is based in Malaysia and travels across the region. Their career covers both sides of wire bonding:
- Equipment side: bonder field service and process development, including hardware and software upgrades, benchmarking and training for engineers and technicians.
- Production side: leading front-end-of-line NPI and wire bond process development in high-volume semiconductor assembly, including gold-to-copper conversion that qualified dozens of devices into production.
- Process control at scale: portability calibration and central recipe management across large bonder fleets.
- Recognised results: formally recognised for resolving complex wire bonding yield problems, establishing robust process controls and releasing products to mass production.
- Training: a certified train-the-trainer, teaching copper wire bonding part-time, with recent formal training in wire bond materials, process and reliability.
Languages: English, Malay and Chinese. Like every member of the network, MY-02 is going through verification. You see the profile code and capability first. Name and contact details are shared once the engagement is confirmed and paid.
6. Consultancy and independence
Because this is consultancy, we won’t then audit the same site’s wire bonding on behalf of a customer for two years, and the specialist never audits work they advised on. Nothing from your engagement is passed to anyone else. See sections 3 and 8 of our independence policy.
7. Price
From S$150 per hour, on site or remote, so you pay only for the time the work takes. Larger work can also be quoted as a fixed project. For on-site work, your quotation adds hotel and transport at cost and travel time.
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