DISCO high precision UV laser repair

DISCO (Japan DISCO) ORIGAMI XP series is a high-precision UV laser cutting system designed specifically for processing brittle materials such as semiconductor packaging, FPC flexible circuit boards, LED wafers, etc. Its core advantages include:

Wavelength: 355nm (ultraviolet), cold processing

Positioning accuracy: ±1μm (with CCD visual positioning)

Cutting speed: up to 500mm/s (depending on material thickness)

Intelligent dust removal: integrated N2 blowing and electrostatic adsorption system

II. Common fault diagnosis and solutions

1. Laser power reduction/instability

Possible causes:

Aging of ultraviolet laser crystal (Nd:YVO₄) (lifespan of about 8,000-10,000 hours)

Surface contamination of frequency-doubling crystal (LBO)

Optical alignment offset (caused by vibration)

Maintenance steps:

Spectral detection:

Use a power meter to measure 355nm output, attenuation>15% requires optical path calibration

Crystal maintenance:

Clean LBO crystal with anhydrous ethanol + dust-free cotton swab (do not touch the coating surface)

Optical path calibration:

Use DISCO special fixture to adjust the reflector angle (authorization password required)

2. Cutting position drift (abnormal accuracy)

Key checkpoints:

CCD camera focus:

Clean the lens and re-perform "Auto-Focus" calibration

Motion platform guide rail:

Check linear motor encoder feedback (ERR 205 alarm is common)

Material fixed vacuum adsorption:

Vacuum degree needs to be >80kPa (clean porous ceramic suction cup)

Quick verification method:

Cut the standard grid pattern and compare the deviation between the design drawing and the actual path

3. System alarm code processing

Alarm code Meaning Emergency processing

ALM 102 Laser head temperature is too high Check the flow of water cooler (need to be >2L/min)

ALM 303 Safety interlock triggered Confirm the status of the protective door sensor

ALM 408 Dust removal system pressure is insufficient Replace HEPA filter (every 500 hours)

III. Preventive maintenance plan

1. Daily maintenance

Clean the residual debris in the processing area (to prevent electrostatic adsorption from contaminating the optical window)

Record laser power data (fluctuation should be <±3%)

2. Monthly maintenance

Replace cooling water (conductivity <5μS/cm)

Lubricate X/Y axis rails (use DISCO specified grease)

3. Annual in-depth maintenance

Full inspection of UV laser optical path (original calibration equipment required)

Vacuum pump oil replacement and seal inspection

IV. Maintenance cost optimization strategy

1. Laser module cost reduction plan

Component Original replacement cost Alternative plan Savings ratio

Nd:YVO₄ crystal ¥180,000 Third-party regenerated crystal ¥80,000 55%

Focusing lens group ¥65,000 Domestic fused quartz lens ¥15,000 77%

Motion control card ¥120,000 Chip-level maintenance ¥25,000 79%

2. Key skills

Extending the life of laser crystals:

Lowering the operating temperature from 25℃ to 20℃ can increase the life by 40%

Certification of domestic consumables:

HEPA filters, vacuum chucks, etc. have passed the DISCO compatibility test

V. Successful cases

A semiconductor packaging plant (5 ORIGAMI XPs)

Problem:

Annual maintenance costs exceed ¥1,200,000, mainly due to frequent replacement of UV crystals

Our solution:

Install a crystal temperature closed-loop control module

Use laser polishing repair instead of crystal replacement

Results:

Crystal replacement cycle extended from 8 months to 3 years

Annual comprehensive cost reduced to ¥400,000

VI. Technical support

Spare parts inventory: UV optical modules, motion control boards, etc.

Remote diagnosis: Analyze equipment logs through the DISCO Connect platform

Get customized maintenance solutions

Contact our laser maintenance experts for free:

"ORIGAMI XP Alarm Code Quick Reference Manual"

Your equipment health assessment report

Practice localized services with Japanese process standards to ensure efficient and stable operation of precision cutting equipment

—— DISCO laser equipment maintenance service provider in Asia Pacific