The Gel-Flex Tooling System:

A less expensive, astonishingly simple solution that radically reduces changeover times in manufacturing double-sided boards.

Conformal Board Support System

This revolutionary conformal tooling solution is based on innovative use of ESD-safe polyurethane gel.
It provides firm board support during printing — combined with gentle, damage-free compliance to your bottom-side components and leads.
It’s the solution high-mix manufacturers have been waiting for. The unique Gel-Flex system offers an elegantly simple design without moving parts, air lines, or wiring.

The Gel-Flex system offers:
• Increased uptime
• Fastest setups and quickest changeovers, even for large, double-sided boards
• Improved yields due to less component damage
• Minimal maintenance
• Lowest cost of ownership (typical ROI in less than 3 months)
• Simple, customer installable field upgrades
• Very intuitive — minimal operator training required & Fits Your Specific Application

The Gel-Flex system is the optimum answer for PCB assembly lines featuring moderate to high
product mix or operations requiring more than one changeover per day. It’s the ideal tooling solution for:
• Contract electronics manufacturers
• OEMs
• Manufacturers of high density boards
• Prototype labs

The Gel-Flex solution is simple; provides payback in months; is quickly adaptable; and doesn’t require elaborate setups or time-consuming changeovers. Instead you get flexible, customized, stress-free support for superior printing of all kinds of boards – including large, densely populated, routed double-sided boards.
Offers Unique Features
• ESD safe, compressible polyurethane elastomer gel supports provide:
– Gentle compliance to delicately support bottom-side components and leads with damage-free, firm
support across the entire board
– Elastomer membrane shells protect boards from solvent and printed medium contamination, while
increasing support durability
• Quick-position magnetic bases for fast and easy product setup
Operation as Easy as 1-2-3
With the Gel-Flex system, there are only three simple steps required to set up or change over from one board to another. Since there are no pneumatic or mechanical connections, and precise support positioning is not required even for densely populated double-sided boards, each changeover should require less than 60 seconds.
Step 1: Adjust conveyor rails to the width of the board (accomplished during normal programming of the printer)
Step 2: Position Gel-Flex metal side supports along the left and right ends of the board
Step 3: Distribute Gel-Flex supports evenly under the board surface

GEL-FLEX SYSTEM SPECIFICATIONS
Maximum board thickness Equal to target printer specifications
Minimum board thickness 0.030” (0.76mm)
Maximum board size Equal to target printer specifications*
Maximum component height** 0.200” (5.1mm)
Maximum component density No limitation
Board support setup time Typically less than 60 seconds
Setup templates None — precise positioning not required
Air requirements None — air not required
Power requirements None — power not required
Maintenance requirements Wipe occasionally with damp cloth
Life-cycle of Gel-Flex supports More than 12 months with proper use
Installation time for field upgrades No installation required — immediately ready for use.
Note! Large thin boards may need supplemental centrer-board support.
Note! Boards with components greater than 0.200” (5.1mm) can be accomodated by locating Gel-Flex supports in positions that avoid these extra tall components.

 

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