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of circuits are produced on a single silicon wafer. Microchip makers want to yield the maximum number of circuits off that platform. “It’s a 12-in. piece of silicon, yet


it has all this value,” Meadors said. “The industry is striving for smaller and smaller circuits and that means we have to have even more consis- tent heaters and part to part repeat- ability. Every heater we produce has to be absolutely perfect.” At CAS, the design of a cast-in heater starts with thermal engineer- ing—determining the best shape for the cooling tube or heating element to achieve a target uniform temperature. Te CAS engineering team uses finite element analysis (FEA) to optimize its designs and migrate them to manu- facturing. Tis process also employs process simulation models to evaluate and establish the location of flow-path tubes and heating/cooling elements within the mold.


Shown are CAST-X circulation heaters midway through production. “We look at things first from a


thermal standpoint,” said Eric Hostert, CAS vice president–engineering and quality. “Te heater’s location in the mold could affect the component’s performance. How the molten alumi- num flows is also important. We can’t


have voids or inclusions that might inhibit our products from achieving a uniform temperature.” Maintaining a uniform tempera-


ture is important in myriad applica- tions. In commercial quick-service restaurants, for instance, a consistent


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