THE CHALLENGE
The electrostatic chuck is the foundation of many microchip manufacturing operations. It supports silicon wafers as they are processed to make microchips. A ceramic coating on the chuck protects it from the erosive, high-energy environments used to fabricate chips, and a durable coating can provide a competitive edge for chip manufacturers. Our client needed to develop a testing strategy that could determine the lifespan of their chuck coatings — and they turned to Exponent to make it happen in days, rather than months.
EXPONENT'S MULTIDISCIPLINARY SOLUTION
Exponent's team of multidisciplinary experts worked together to design a test fixture, re-create failure modes, and test physical samples. Engineers and scientists specializing in thermodynamics, vacuum systems, process control, optical profilometry, and fracture mechanics came together to create a streamlined test regiment for our client.
Our Impact
Exponent's novel test design accelerated the evaluation of new electrostatic chuck coatings from months to days. The insights provided by Exponent's custom testing protocol are allowing our client to rapidly improve their production designs through data-driven decision-making.
Our ability to develop both custom testing fixtures and associated protocols to conduct rapid testing of materials and equipment is supporting advancements in microchip manufacturing and helping to meet the ever-growing demand for microchip production and performance.
What Can We Help You Solve?
Exponent materials and corrosion experts can help you with materials wear assessment through every stage of the product lifecycle, from development to production to product improvement. Exponent can develop and conduct unique tests to simulate real-world conditions and wear for a wide variety of products and applications.
![Worker in a factory setting examines a large pipe. Mechanical engineering expertise for all types of corrosion and materials challenges.](/sites/default/files/styles/cards_home_card/public/media/images/GettyImages-890706334.jpg?itok=_NudFsFz)
Materials & Corrosion Engineering
Valuable insights for your most formidable materials and corrosion engineering challenges.
![Extraordinary Tools_Natick Lab-1](/sites/default/files/styles/cards_home_card/public/media/images/Careers-Life%20at%20Exponent-Extraordinary%20Tools-1_980x580.png?itok=7dXQDbnt)
Design Evaluation & Materials Selection
Quantifiable, evidence-based information for better materials selection and business decisions.
![Exponent has electrical engineering and computer expertise to assist clients with electrical materials and packaging.](/sites/default/files/styles/cards_home_card/public/media/images/Electrical%20Materials%20%26%20Circuit%20Packaging.png?itok=NxhBssos)
Electrical Materials & Circuit Packaging
Overcome challenges in electrical materials and packaging, such as semiconductor and dielectric materials.
![A worker sorts polymers in manufacturing assembly. Exponent polymer science and materials chemistry consulting.](/sites/default/files/styles/cards_home_card/public/media/images/GettyImages-177470402.jpg?itok=vIAp1jWM)
Polymer Science & Materials Chemistry
Multidisciplinary support for materials challenges for diverse clients and applications.
![Exposed rust and flaking material on an exterior surface. Exponent materials and corrosion engineering support.](/sites/default/files/styles/cards_home_card/public/media/images/GettyImages-1302662890.jpg?itok=1eWGJWek)
Materials, Metallurgy & Corrosion Engineering Capabilities
Assess corrosion risks and follow best practices in materials selection, operations, and corrosion control for metals.
![A person sitting in a train wearing headphones. Exponent helps manufacturers improve the quality and performance of consumer products.](/sites/default/files/styles/cards_home_card/public/media/images/GettyImages-1390405754.jpg?itok=tFVWQQZB)
Materials & Corrosion Expertise for Consumer Electronics
Expert materials and corrosion analyses for consumer electronics.