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JULY 2025 I PCB007 MAGAZINE 41 D R I V I N G I N N OVAT I O N this trend, particularly among manufacturers pro- ducing high-end, high-density, or large-format PCBs. These manufacturers are now investing in advanced post-etch punch technology as an inner layer alignment solution. This change is driven by the precision capabilities that modern post-etch punch machines offer: • Top and bottom cameras for alignment: Modern post-etch punch machines feature high-precision cameras positioned on the top and bottom of the panel (Figure 3). These systems compensate for any potential mis- alignments between the top and bottom sides of an etched inner layer. By individually measuring and compensating for each side, these machines ensure optimal alignment and compensation of internal layer shifts. • Integrated measurement system as a criti- cal control point: The integrated measure- ment system within a modern post-etch punch machine transforms it into a vital con- trol point for the entire PCB fabrication pro- cess. Beyond punching holes, the machine accu- rately measures the dimen- sions and fiducial locations of each inner layer before it proceeds to lamination. This provides invaluable feedback, allowing manu- facturers to: » Validate each layer: Identify and, if nec- essary, discard inner layers that are out of tolerance before consuming additional valuable resources in subsequent, more costly, production steps. » Process monitoring: Collect data on layer distortion or etching consistency, which can be used to fine-tune upstream pro- cesses and improve overall yield, signifi- cantly reducing scrap and rework costs. • Perfect tools and special double tooling systems: Achieving perfectly consistent holes on panels of varying thicknesses is par- amount. High-end post-etch punch machines utilize robust, precision-engineered tools and often incorporate specialized double tooling systems. These systems ensure clean, con- sistent hole quality regardless of the material thickness (Figure 4). Up to 4 Top CCD Camera Up to 4 Bottom CCD Camera ▼ F i g u re 3 : S c h e m e s h ow i n g t h e l o c at i o n of t h e c a m e ra s i n to d ay 's a d va n c e d p u n c h m a c h i n e s . ▼ F i g u re 4 : P h oto of p u n c h e d h o l e s .