Kappler & Blaser: Working hand in hand to achieve a clean process in the production of complex electronics
Kappler CNC is a high-tech company from Birkenfeld, in Baden-Württemberg, Germany, producing complex parts for demanding environments such as in chip production, as well as the aerospace and electronics industries. The challenges here are immense, not only in terms of precision, but also cleanliness – with cleanroom compatibility being a prime example. Kappler specialists are working in close collaboration with Blaser Swisslube’s metalworking fluid experts, as part of a comprehensive development process, to establish an ideal product for the specific production needs. A partnership geared to the future that is bearing fruit already.
Kappler CNC, founded in 1934, is an innovative precision engineering production company located in Birkenfeld, in Baden-Württemberg, Germany. The family business, which is now being run by the family’s third generation, employs around 200 staff. The company originally produced bench drilling machines – but over the decades, Kappler has succeeded in progressively diversifying its production. Today, the high-tech company focuses on producing complex and challenging parts from aluminum and various stainless steels, for the chip and optics industries, aerospace and medical technologies, the energy sector, as well as mechanical engineering and electronics.
Machine operator Mr. Müller in action.
“The electronics segment is particularly demanding. Here, it is essential that the parts produced are cleanroom compatible. So it must be ensured that the parts can be optimally cleaned and are free of extraneous substances,” explain Kappler specialists Christian Huber, project manager, and Jürgen Klittich, responsible for tool purchasing and metalworking fluids. Mr. Klittich has worked for the company for more than 20 years – more than two decades in which Kappler CNC has been resolutely committed to maintaining its technological edge and growing its expertise. Jürgen Klittich: “Kappler strives to take new approaches and to achieve extraordinary things!”
Kappler is pursuing one of these new approaches together with Blaser Swisslube: The company contacted the metalworking fluid specialists at Blaser in early 2021, with a specific problem in the particularly demanding area of machining components for EUV lithography systems. According to customer specifications in the electronics sector, an alternative to the oil-based metalworking fluid used up until that point had to be found that offered the greatest possible degree of cleanliness. Stains on the produced parts and contamination, e.g. from silicon or phosphorus during the manufacturing and cleaning process, was to be prevented.
“In the electronics segment and especially with EUV lithography systems, cleanliness in manufacturing is a very important and complex matter. The smallest residues of certain elements on the components can subsequently damage the optics in EUV systems. Materials used in machines, the greases used – every parameter, no matter how small, can have a negative impact on the result,” explains Andreas Neumann, Segment Manager Electronics at Blaser Swisslube. “That’s why teamwork between the producer, the customer, the machine manufacturer and the metalworking fluid expert is so important. Synergies must be harnessed.”
Thorough final measurements: the highest-possible degree of precision takes top priority.
Experts from Kappler and Blaser Swisslube in dialog.
Jochen Rühle, Regional Sales Manager South at Blaser Germany, adds: “The detailed on-site analysis, in close collaboration with the Kappler specialists, is a joint learning and development process. Initial tests with a first coolant in 2021 looked promising, but we then decided on B-Cool Eltec 502 since this emulsion also dispenses with critical hydrogen-induced outgassing (HIO) elements, such as silicon, phosphorus, zinc and tin, and is particularly suitable for processing components in EUV lithography systems. It was also a goal of ours to use the same metalworking fluid throughout production.”
Thanks to its special, HIO-uncritical formulation, B-Cool Eltec 502 supports users, e.g. in meeting the cleanliness requirements (grades) of ASML, the world’s largest supplier of lithography systems for the semiconductor industry. Some requirements do not allow the use of a fully synthetic metalworking fluid. Blaser’s portfolio of HIO-uncritical products allows solutions to be found, even where this is the case. B-Cool Eltec 502 is a water-miscible, chlorine-free and semi-synthetic metalworking fluid that features excellent aluminum compatibility and is easy to clean. The product is universally applicable and excels with its low foaming tendency, excellent corrosion protection and outstanding surface cleanliness.
The first machines were filled with B-Cool Eltec 502 in March 2022. “From testing and analysis at Blaser in the lab to production and fine-tuning in a critical environment in the Kappler production facility – for us, it is an ideal collaboration for establishing a successful, stable product in the long term,” Klittich emphasizes.
“In the electronics segment and especially with EUV lithography systems, cleanliness in manufacturing is a very important and complex matter. The smallest residues of certain elements on the components can subsequently damage the optics in EUV systems. Materials used in machines, the greases used – every parameter, no matter how small, can have a negative impact on the result,” explains Andreas Neumann, Segment Manager Electronics at Blaser Swisslube. “That’s why teamwork between the producer, the customer, the machine manufacturer and the metalworking fluid expert is so important. Synergies must be harnessed.”
High-tech company Kappler CNC produces parts for demanding industries.
Kappler and Blaser Swisslube: synergies through teamwork.
