MANUFACTURING Why fume extraction in electronics Graham Mattok M
manufacturing is critical By Graham Mattok, UK and Ireland manager at Donaldson BOFA, which design, develop and manufacture portable fume and dust extraction solutions for a wide range of industrial sectors and applications.
anaging fume and gaseous organic compound emissions has long been important in electronics manufacturing. Effective fume and particulate extraction helps electronics manufacturers protect their equipment, support product quality and maintain a clean workplace environment. However, in recent years the growing complexity of microelectronics, coupled with the miniaturisation of components, has intensifi ed the need for precision air quality control. Even microscopic contamination can result in solder joint failures, short circuits, or diminished performance.
The demand for speed places greater emphasis on automation and the integration of all the constituent parts of the manufacturing process. For fume and dust extraction systems, this means investing in technical innovations that deliver an airfl ow management and fi ltration architecture that can capture emissions effectively, while stretching the periods between fi lter exchanges. This will help electronics manufacturers to minimise downtime while increasing operations effi ciency and controlling costs.
In one documented case study, moving to new technology with larger capacity fi lters and enhanced airfl ow met the customer’s automated and manual soldering production requirements, while providing lifecycle cost reductions. Although results may vary depending on application and environment, this specifi c customer reported replacing fi lters ten times less frequently, achieving payback in just a few months.
Portable fume and dust extraction systems are increasingly becoming a feature of automated electronics production processes, including for wave and refl ow soldering in factories producing high-volume, high-quality PCBs. Portable systems are also agile, enabling fume extraction systems to be moved easily when production lines need to be reconfi gured.
Why fume extraction is essential for wave and refl ow soldering
In wave soldering, PCB components are placed on the board and passed over a
continuous wave of molten solder. Areas not to be soldered are covered with a protective ‘mask’. While this process doesn’t usually involve the potentially harmful resin/ colophony present in hand soldering, it can require the use of an alcohol-based solvent such as Isopropyl Alcohol (IPA) and a small amount of organic acid, fume from which needs to be fi ltered. Before soldering, the boards are ‘spray fl uxed’, using either a general spray process, which can generate airborne dispersions of fl ux particulates and vapours, or a targeted jet from a robotic nozzle.
With refl ow soldering, solder paste is applied to the PCB and components are ‘picked and placed’. The board moves through various heating, stabilising and cooling zones, during which the solder metal ‘refl ows’ or melts and solidifi es around the component connection. During this process, the solvent that makes the paste liquify will evaporate. All of these airborne emissions need to be fi ltered through a fume extraction system. A temperature control unit (TCU) can help maintain optimal PCB print area temperatures in automated production lines. This is crucial for solder reliability, component placement accuracy, defect reduction and production consistency. Even small deviations can lead to major yield loss or reliability issues.
It’s all in the detail To achieve these goals, air fi ltration engineers should undertake a detailed assessment of
the industrial process, the materials being worked, and the volume and composition of the fume or particles being emitted. This should include detailed mapping of the airfl ow management parameters, to set the correct capture velocity (the speed of suction) that is required to satisfy local emissions regulations. These desktop analytics should then be proven through a process of application testing, to underscore the anticipated benefi ts with rock-solid performance data.
The resulting systems should be tailored to specifi c workplace exposure limits set under the Control of Substances Hazard to Health (COSHH) regulations. One fi lter media to consider is HEPA fi lters as they provide a very high level of fi ltration for both the smallest and largest particulate contaminants. They send air through various pre-fi lters to assist with catching airborne particulate, capturing 99.995 per cent of particles at 0.3 microns. An effective fume and particulate extraction system will contribute to optimal automated electronics manufacturing performance through effective air management and multi-stage fi ltration technology. This should include specialist activated carbon fi lters designed to capture specifi c chemical emissions. It is clear that effective fume and particulate extraction plays an important part in helping electronics manufacturers create a clean environment for their teams while maintaining high levels of quality and productivity.
DECEMBER/JANUARY 2026 | ELECTRONICS FOR ENGINEERS 29
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