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32 I-CONNECT007 MAGAZINE I FEBRUARY 2026 Adapting the Machine Platform The foundation of any large-format process is the machine table. To handle XXL dimensions, the platform must be adapted from the start. It is crit- ical to define maximum panel dimensions in the early planning stages. Look for a standard drilling machine that can be adapted to handle panels up to 49 inches at each of six individual stations. We have been able to convert six-station machines into a single, massive one-station unit that unites all processing areas into one, and we have delivered systems adapted for panels as large as 131 inches. Some machine platforms also could be optionally equipped to work in step mode, which allows for processing of non-limited sizes of the boards in one direction (typical solution for flex boards, but could be adapted as well for super long rigid boards). Solving the Warpage Challenge Large panels are inherently less stable. Non-sym- metrical designs, material inconsistencies, and thermal stress at different process stages create significant warpage. If a panel is not flat during its processes, the focal point of a light source or the depth of a mechanical drilling might be inconsis- tent across the surface. " Modern systems are designed for high flexibility through clever operating modes." Anti-warpage solutions are mandatory for XXL handling. These include: • Special clamping: Side-mushroom clamps or customized perimeter clamping • Auto-focusing: Systems which adjust the Z-height in real-time to follow the "hills and valleys" of a warped panel • Vacuum tables: Ensuring the panel is pulled perfectly flat against the machine bed. In X-ray registration processes, for example, a full-table vacuum is often the only way to ensure the internal layers are accurately mapped. Precision Through Self-calibration When a machine operates on a high-precision coordinate system—X and Y axes represent the coordinates on the panel, while the Z-axis houses the processing unit (spindle, laser, X-ray source, or punch)—the alignment between this processing unit and the table with panel positioned on it is the key for accuracy. While this alignment is perfected during factory assembly, the physical forces and ther- mal changes involved in XXL processing require constant vigilance. To maintain micron-level preci- sion, machines must be equipped with self-check (optionally also with self-calibration functions) and maintained properly. Self-calibration func- tions allow the machine to check its own alignment during production, compensating for any drift with- out human intervention. Flexibility: Small Panels on Big Machines Investing in an XXL-capable machine does not mean sacrificing efficiency on standard jobs. Modern systems are designed for high flexibility Figure 2: Drilling machine adapted for 131-inch panels. Figure 3: Full table vacuum on X-ray process. D R I V I N G I N N OVAT I O N