Complete PCB production in a small space

2021 was Bungard 60th Anniversary

At the beginning, in 1961, company founder Heinz Bungard in Leverkusen considered opportunities for further development in the young industry of printed circuits. It was his idea to equip the copper sheet of a PCB with a UV-light sensitive fotocoat and so he is considered to be one of the inventors of the world-wide-known presensitized PCBs.

The Presensitized Base Material is still the major column of the Bungard product portfolio. In addition, the company has developed into a reliable and important partner as a supplier for the PCB manufacturing companies. When Bungard started production and distribution of the Presensitized Base Material, they were already thinking about supplying small-scale processing equipment for all customers of the Bungard base material. This market segment was so far totally ignored; e.g. it was impossible to obtain small etching machines or exposure units.

At first glance, all the Bungard equipment looks like a production of printed circuit boards in Legoland format. But on closer inspection, the viewer learns that the products are the result of decades of experience and thought.

Making PCBs with Presensitized Base Material

Any manufacturer of designs, prototypes or small series was now able to produce fast, flexible and above all, error-free PCBs in-house. This was reflected even then in the slogan: “In the morning on the drawing board, at noon already done – with original Bungard Presensitized Base Material”. The company’s founder gave his word with his name and his experience for the quality of original Bungard Presensitized Base Material. Only top quality materials, tested and approved by all usual standards, are used.

A broad range of materials such as FR2, CEM1, FR4 and PTFE in various board thicknesses and with different copper clads are offered. From 570 mm x 1150 mm wide boards, all standard and special sizes down to a minimum of 50 mm x 50 mm are cut. For the photocoat a high quality positive liquid resist is used, made according to a Bungard owned recipe. The resist features highest exposure sensitivity, short processing turns and large safety tolerances. To paraphrase an advertising slogan: The plates are “indestructible”. With controlled 5 micron layer thickness the resist provides the conditions for rapid and thorough exposure. Tthe optimum light source is at 400 nm and the optical resolution less than 30 microns. With the Hellas exposure unit, exposure takes about 90 seconds. Each board can leave the special developer after approx. 45 seconds at 20C. To protect the photocoat from dust, mechanical damage, and unwanted exposure, all materials are covered with a blue foil. Based on the experience with presensitized PCBs, Heinz Bungard extended his product range. In 1981 he started selling aluminium panels, which unerwent a special treatment sequence and then coated with a positive photo resist. Alucorex, the new product’s name, aimed to make manufacturing of front panels, signs, as well as pad printing significantly easier. Also, for the SMT stencils or model components, Bungard offers photo-coated brass or German silver plates that can be processed quickly and economically. These are optional positive or negative photocoated which can processed in the same machines, with the same chemistry and with no interference of existing internal processes.

Chemistry under control

Bungard provides solutions for all major upstream and downstream operations during the PCB production process. These solutions are the NE-Cut board cutter with a cutting width of 530 mm, the Filmstar raster photoplotter with 8000 dpi resolution, and the Hellas exposure unit with a parallel light exposure. Typical industrial etching machines are very large. Bungard etching machines consist generally of just one unit. The customer can choose between a stationary spray etching machine for either single or double sided boards or a conveyorized spray etching machine.

  • The Splash-Center is a wet processing equipment with static rinse, spray rinse, integrated developer, reserve pool for immersion tin and squeeze dryer
  • The DL 500 conveyorized flow system is popular for its clean working procedure. The user can take out clean boards without contacting the chemicals – important in all industries but especially useful in the educational environment. The DL 500 throughput is more than 5 times the throughput compared to other laboratory etching machines. Small PCB series can be produced easily and quickly.

Whenever you use chemicals a wastewater treatment plant is a useful option. With space requirements of less than half a square meter the wastewater treatment plants fit perfectly into small PCB laboratories. The user receives a compact system with a complete closed circuit where nothing is released to the outside, because all substances are taken out of the waste water and demineralized water is flowing back to the machines or the drain. This is guaranteed by two or three ion exchange columns and, depending on the type, a mineral ph-level-column. The PCB-manufacturer can choose from four models with varying flow rate and absorption capacity. As an entry level solution Bungard supplies a mechanical through-hole-plating press. Hollow rivets are fitted into the drill holes of a double-sided circuit boards and are then pressed onto the board. Even laboratory manufacturers without any mechanical knowledge will be able to this job.

Bungard offers both etching and CNC milling products.

Technician Plug in Cpu Microprocessor to Motherboard Socket
Technological Background With Closeup on Tester Checking Motherboard

Bungard Products

Bungard can provide a complete line or individual units.

  • Photoplotter
  • Brushing Machines The Bungard RBM-series proves: Professional brushing machines at reasonable prices are possible. Both machines have height adjustable brushes, adjustable oscillation and transport speed as well as fully squeeze-off and dry zones
  • Dry Film Laminator The RLM is a dry film laminator especially made for small companies, schools, research and development departments
  • Exposure Units Bungard offers two different types of exposure units to meet your demands: Hellas is a precise vacuum exposure unit with super actinic fluorescent tubes, whereas EXP 8000 is a high performance exposure unit with double sided mercury halide lamps and UV counter/sensors
  • Etching and Developing The Bungard spray etching machines combine industrial quality with a small need of space. It doesn’t matter whether you want to etch only one side, two sides or if you prefer a flow path machine, we offer a solution for almost every task
  • Through Hole: Rivets or Plating We recommend two different variants to achieve a high quality through hole plating: for simple pcbs the riveting press FAVORIT offers a very cheap but effective mechanical solution. For more sophisticated boards the use of the chemical/galvanic plating through hole (PTH) method is recommended
  • Solder Mask / Tinning Here you will find various possibilities of surface design in printed circuit boards. We hope to give you an interesting overview and are happy to provide more detailed information to you when requested
  • Multilayer Press This high performance multilayer press was designed for PCB labs to enable quick prototyping of multilayer PCBs according to industry standards. The number of layers is only limited by the maximum lift of the press compartment Dip Coater This machine is the successor of the approved gear motor driven RDC 15 and was developed to meet the demand for a greater variety of speeds and settings
  • Water Treatment The name IONEX stands for ION-EXchanger, which is the very heart of this modern waste water treatment system CNC Milling Process The Bungard CCD is a high-end computer operated CNC Machine. Available in different table sizes and with automatic or manual tool change. Together with the machine control software RoutePro 2008, the IsoCAM 3.0 software for converting design data into CNC Data and the various drills and cutters the CCD is a professional tool for a wide range of tasks in electronic laboratories, model building and PCB production. The CCD allows the direct use of Excelleon or Sieb/Meyer drill data, HP-GL data for manufacturing PCBs (Drilling, Routing, Isolation milling) or routing/engraving of plastic, aluminum and other metals. With optional ISOCAM PRO software, even import of Gerber and DXF and Bitmap data is possible!
  • CCD-2
  • Laser Direct