Inspecting for Bent IC Lead Terminals


Bent or lifted IC lead terminals can compromise product reliability. Misaligned leads might not sit flat on the PCB, causing intermittent connections, solder defects, and the need for rework. Zebra’s inspection solution can leverage Iris GTX smart cameras, AltiZ 3D Profile Sensors, and Aurora Machine Vision software to monitor lead position and flatness in real time. It classifies edge cases and makes inline decisions to enhance first-pass yield. These solutions ensure each lead is straight and level before soldering. Inspection results are stored with lot and device IDs to aid traceability and speed up root-cause analysis.

Machine Vision Frame Grabber Photography Application Semiconductor Terminal Inspection 4x3 3600

Detect bent leads early with integrated 2D and 3D inspection to increase first-pass yield and stabilize solder quality

Zebra GTX Bent IC Terminals (Callouts) on Assembly Line

Speed 2D inspection for bent-lead detection

At the forming or placement station, an Iris GTX smart camera captures high-speed, high-resolution images of every package to accurately measure the lead position, pitch, and coplanarity from calibrated images. This process helps identify any bent, lifted, or splayed terminals before they reach the soldering stage. The results are shared in real-time with the Programmable Logic Controller (PLC) and line-reject mechanism, ensuring that any nonconforming parts are swiftly removed to maintain smooth and stable throughput. 

Altiz 4200 Photography Application Scans Semiconductor Pins 16x9 3600

Add 3D profiling to catch tough defects

AltiZ 3D Profile Sensors feature single camera or dual-camera, single-laser designs to capture precise height data without relying on image contrast. 2D measurements can be fused with 3D profiles to confirm coplanarity and lead tip height. This reduces false positives on reflective metal. Results are then communicated to the PLC and reject mechanism, allowing any detected issues to be addressed before reaching the soldering stage.

Software Aurora Imaging Library Photography Website Pin Inspection 16x9 3600

Improve audit trails and error handling

Aurora Imaging Library stores real-time measurement data with lot and device IDs for traceability. Configurable recipes include versioning and change logs for change management. Track first-pass yield and statistical process control trends using control charts and alerts, helping engineers address tooling or process drift before defects accumulate. The system handles errors with automatic retries, manual review routing, or line-stopping, and archives images and results for audit trails. In inspecting bent IC lead terminals, the library ensures precise traceability and accurately identifies bent terminals, while detecting trends for early intervention. Error management and archiving ensure systematic recording and easy retrieval of bent terminal findings.

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