Figure 1 Figure 2 Figure 3

This is a medical CO2 analysis system. The main board, Figures 1 and 2, is a 6 layer design, 8/8, mixed low level analog, digital, and switch mode power supplies. There are in excess of 500 components on the 80 x 120 mm board, which features an isolated power supply with integral 4.5KV spark gap and a buried capacitor for "tuning" to meet stringent EMC specifications. Minimum component pitch is 0402 passive; .019 active. The back of the board, Figure 2, contains at least one ICT pad for each circuit node.

Figure 3 shows the complete system, with 2 daughter boards and a pump for sample acquisition. Maximum height is 20mm. Laser trimmed hybrids are used where precision calibration is desired.
Figure 4
The flex circuits in Figure 4 are used in an external sensor for the above system. The top part is a rigid flex, 3 layer, 6/6, 0603 components, used in the sensor body. Bottom part is a standard flex with kapton stiffeners, 7/7, 2 layer, 0603 components, which mounts in the connector body. Replacing the original rigid boards and many hand-spliced "flying leads" with these flex circuits resulted in a 20% savings in assembly costs.

Figure 5 Figure 6
Figures 5 and 6 are a radar receiver used in ionospheric physics research, wind profiling, and bird and insect migration studies. Top board is the RF section; center board a Bessel filter; bottom board is the baseband module which holds 8 of the filter boards. Figure 6 is a top view of the completed assembly.