Costly delays in PCB assembly often stem from rigid, high-volume systems. Xalten Systems redefines flexibility with a compact, precise pick-and-place solution built for efficiency and seamless scaling. Electronics For You’s Akanksha spoke with Dr K C Unnikrishnan and Ajith Narayanan to explore how their system ensures accuracy, smooth integration, and a rapid learning curve.
Q. Can you briefly explain Xalten Systems, focusing on key milestones?
A. For Xalten Systems, the work began in 2017, initially focused on developing an efficient prototyping machine to handle tiny and intricate components. By 2019-2020, we launched the first version of our product at EFY’s IoT Show and India Electronics Week. Despite challenges like the COVID-19 pandemic and a global chip shortage, we successfully redesigned our product for greater flexibility and efficiency. Today, after the rebranding, our machines are used for both prototyping and small-batch manufacturing.
Q. What makes desktop pick and place machines ideal for prototyping and small-batch production?
A. Our machines offer flexibility and ease of use, for example, allowing for pick-up of components randomly placed in a tray, which the machine accurately picks and places. This capability is particularly advantageous for handling small quantities, reducing setup time, and minimising waste, making them ideal for startups, R&D labs, and quick prototype turnarounds.
Q. How does your Pick and Place machine’s precision compare to larger, traditional machines, and what key features set it apart from competitors?
A. Our compact system maintains high precision, effectively handling small components in tight spaces. While it may not match the speed of large industrial machines, it offers flexibility and ease of use, making it ideal for smaller production runs. The machines are designed for user accessibility and efficiency, with a minimal learning curve and quick setup. This allows for rapid initiation of component placement, even on PCBs of arbitrary shapes, ensuring complex designs are executed smoothly without compromising precision or speed.
Q. How do you ensure placement accuracy, and what is the max component size your system can handle?
A. Our machines manage a wide range of component sizes with consistent precision, accommodating components as small as 0.5mm x 0.3mm to 40mm x 40mm in specific configurations. Advanced algorithms and a robust suction mechanism ensure precise placement across this size range, avoiding the common industry practice of overstating capabilities.
Q. How does your system adapt from prototypes to small-scale production, and what are the critical considerations for scaling?
A. Our machine is designed to transition smoothly from prototyping to small-scale production, offering features like dual heads for simultaneous operation and automatic paneling options. These options enable users to switch from single to panelised PCBs without extensive reconfiguration. When scaling, it is crucial to consider production volume and component complexity. For moderate production levels, using multiple machines might be more cost-effective, whereas very high volumes may necessitate investing in larger systems to maintain efficiency and accuracy.
Q. Is the machine scalable for larger production, or only suitable for desktop use?
A. Our machine is best suited for small to medium-scale production and desktop use, ideal for prototyping and low-volume manufacturing. Multiple units might be deployed for larger production environments, but other systems might be more appropriate for very high volumes.
Q. How intuitive is the interface, and how well does it support rapid prototyping?
A. Our software interface is highly intuitive, built on an open-source platform with enhanced features for an improved user experience. New users can typically grasp 80% of the functionality within a 30-minute to 1-hour walkthrough, while advanced features may require about a day of training. User-friendly elements like camera views, drag-and-drop functionality, and customisable component lists significantly speed up the prototyping process.
Q. How does the machine’s vision system handle component recognition and alignment?
A. The vision system in our desktop pick-and-place machines is optimised for precision, using advanced algorithms and high-quality imaging to ensure accurate component placement. The system adapts to various sizes, contributing to the machine’s overall accuracy and reliability.
Q. How does your system ensure smooth operation from design to assembly, integrating with solder paste printers and reflow ovens?
A. Our system is optimised for seamless operation from design to assembly. While we do not have an automatic stencil printer, we provide a manual setup for stencil printing. After the pick-and-place process, the board is ready for reflow in the oven, efficiently completing the assembly workflow.
Q. Can you explain the importance of PCB penalisation and how your system manages it?
A. PCB penalisation groups smaller PCBs on a larger board, optimising manufacturing efficiency and reducing handling time. Our system supports panelised boards, crucial for users transitioning from prototyping to larger-scale production.
Q. What type of customisation is available to meet specific customer needs?
A. We offer various customisations, including modifications to feeder configurations, PCB holding arrangements, and machine working areas to accommodate multiple component shapes and sizes. Custom fixtures and nozzles can also be designed to meet specific industry standards or unique component requirements.
Q. What is the machine’s total cost, including purchase, maintenance, and operation?
A. The total cost of ownership varies depending on the model and customisation. Entry-level models start at around 350,000and can go up to 650,000. This price includes the machine’s purchase, initial setup, and basic training. Maintenance and operational costs are relatively low, making it a cost-effective solution for small to medium-scale production.
Q. What is the expected ROI, and are there hidden costs like updates, licensing, or proprietary parts?
A. ROI typically occurs within one to two years, depending on factors like product complexity and profit margins. There are no hidden costssuch that our software is open source with no licensing fees. Extra feeders may be needed, which is standard. Maintenance contracts are optional, and no proprietary components lock you in ongoing costs.
Q. How does the cost-effectiveness of desktop pick-and-place compared to outsourcing prototype assembly?
A. Desktop pick-and-place systems are cost-effective after five to ten production cycles, depending on board complexity. In-house assembly eliminates IP leakage risks and reduces time to market, which is critical in fast-paced industries. Additionally, in-house assembly provides valuable insights into design improvements and yield optimisation, contributing to overall cost savings.
Q. How does “Make in India” affect your desktop pick-and-place machine strategy?
A. The “Make in India” initiative is central to our manufacturing strategy, aligning with our goal of building local capabilities and supporting the domestic supply chain. Our local production enhance India’s precision electronics manufacturing capabilities.
Q. How do partnerships enhance your system’s capabilities?
A. Partnerships are crucial, especially in areas where in-house capabilities are limited. Collaborations with trained suppliers and support from initiatives like the Ministry of Electronics and IT (MeitY) are key to developing and enhancing machine features. We are also exploring partnerships outside India to support international expansion, focusing on establishing a physical presence in key markets through distributors or local support centers.
Q. How does automation, AI, and IoT impact your prototype manufacturing?
A. We are actively working on integrating AI and IoT capabilities into our machines. AI enhances automated inspection and quality control, while IoT enables real-time monitoring and data collection. These features align with Industry 4.0 and smart manufacturing trends, enhancing precision, repeatability, and efficiency in prototype manufacturing.
Q. What are the primary risks associated with setting up operations in India?
A. The primary risks include managing local supply chains, which can be more costly than sourcing from abroad, and challenges in ensuring consistent quality and timely procurement. Additionally, navigating the regulatory landscape, dealing with bureaucratic delays, and ensuring skilled labor availability are significant concerns.
Q. How do you manage risk and control costs in small-batch production while ensuring high quality?
A. We emphasis design for manufacturing (DFM) principles, proper paste application, and accurate reflow profiling to ensure high-quality output. We also document best practices and provide training to help customers optimise their processes, keeping costs low and maintaining high quality.
Q. Can you share any case studies where your machines have significantly improved production efficiency and product quality?
A. One example involves high-end designs used in servers. Customers who initially outsourced board manufacturing faced challenges ensuring quality due to uncertainties about assembly, design, or other factors. By bringing production in-house using our machines, they gained complete control over the product development cycle, improving both efficiency and quality.
Q. Is investing in in-house manufacturing with your machines worth the risk?
A. The investment is worthwhile, as we offer extensive support and customisation, mitigating risks like higher component costs and ensuring quick problem resolution and production control.
Q. How do you evaluate and compare to both domestic and international competitors within the industry?
A. As far as we know, we are currently the only domestic manufacturer of pick & place machines in India. Most desktop SMT assembly solutions in the Indian market are imported, with key competitors being LPKF, NeoDen, Charmhigh, and Mectronics.
