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The Printed Circuit Assembler's Guide to... ™
X-ray Inspection

by: Bill Cardoso, PhD

In this unique approach to X-ray inspection, Dr. Cardoso takes the reader through the history of X-ray technology, beginning with Wilhelm Conrad Roentgen's 1895 discovery of X-rays, which revolutionized medical imaging. This led to the development of modern X-ray machines used in various fields, including electronics. These machines are designed through imaging, motion, and decision steps, with the 1980s invention of the ball grid array (BGA) package simplifying defect detection. Key components include the X-ray source and sensor, with important parameters like focal spot size and pixel size. Imaging configurations, magnification types, and radiation intensity are crucial for system performance. X-ray inspection in electronics manufacturing identifies common defects in SMT assembly, while safety aspects emphasize proper handling, minimizing radiation exposure, and compliance with regulations.



ISBN: 978-1-959894-50-6

Bill started his first company at 17 in Brazil. He sold it a few years later when he was recruited out of college to work for the U.S. Department of Energy’s Fermi National Accelerator Laboratory (Fermilab). At Fermilab, Bill led research in nuclear and high-energy physics to build the equipment that discovered the Higgs Boson (and the 2013 Nobel Prize in Physics). After a decade at Fermilab, Bill was ready to return to entrepreneurial life. He moved from Chicago to sunny San Diego to start Creative Electron in his garage in 2008. Upon the acquisition of FocalSpot in 2016, Creative Electron became the largest U.S. manufacturer of X-ray systems in the electronics industry. Creative Electron’s fast growth has been driven by its artificial intelligence expertise combined with a core competency in X-ray inspection, automation, and robotics. At Creative Electron, Bill leads a team of engineers and scientists who combine AI and X-rays to deliver the most intelligent X-ray machines.

Bill received his associate’s degree in Electronics at 13 and achieved a BS, MS, and PhD in Electrical and Computer Engineering. Bill also has an MBA from the University of Chicago. Bill has written two books and over 200 technical publications. He is also the founder of Scorpion EV, a company that converts vehicles from gasoline to electrical power. Winner of the “2023 Best Engineered Vehicle” at SEMA, Scorpion sells conversion kits and fully built 600hp Cobra replicas. In his spare time, Bill enjoys spending time in the family vineyard with his wife, three kids, and two German shepherds.

Creative Electron is a leading American company specializing in the development and manufacturing of innovative X-ray inspection systems. We focus primarily on providing solutions for quality control and assurance in various industries, particularly in electronics manufacturing (EMS). Our TruView systems are known for their ability to detect defects in solder joints, component placement, and other potential issues that could affect the reliability of electronic devices. We emphasize a user-friendly approach powered by artificial intelligence, ensuring that our X-ray machines are accessible and easy to operate. The TruView product line leverages cutting-edge technology to enhance the accuracy and efficiency of inspections. Our commitment to advancing inspection technology has made us a trusted partner for manufacturers looking to improve their production processes and ensure product quality. The TruView line of X-ray systems ranges from manual 2D and 2.5D machines to fully automated 3D (CT) inline solutions. This range of products allows us to offer solutions to EMS companies of all sizes and budgets.

This book has been technically reviewed by the following experts:

Phil Zarrow President & Principal Consultant, ITM Consulting

Phil Zarrow is the president and principal consultant at ITM Consulting. With over fifty years of experience in PCB fabrication and assembly, he specializes in both through-hole and surface mount technologies. Phil is well-regarded for his knowledge in automated assembly processes, cleaning [...]

Gary Korkala Founder, Kodex, Inc.

Gary Korkala began his career in industrial radiography in 1959 as an x-ray technician at Pittsburgh Des Moines Steel in Baltimore, Maryland, where he used a Cobalt-60 isotope source to inspect welds. He then joined the Westinghouse Nuclear facility in Eddystone, PA, utilizing isotopes and a Van de [...]

Chapter Summaries

  • Chapter 1

    Chapter 1

    In this chapter, the author describes X-ray system components, focusing on the X-ray source and sensor, and key parameters like focal spot size and pixel size.

  • Chapter 2

    Chapter 2

    X-ray imaging configurations, magnification types, the parallax effect, and radiation intensity, along with various imaging modalities (2D, 2.5D, pseudo 3D, and 3D) are covered in this chapter.

  • Chapter 3

    Chapter 3

    Learn about X-ray inspection in electronics manufacturing, common defects in SMT assembly and their identification using different X-ray imaging modalities.

  • Chapter 4

    Chapter 4

    This chapter focuses on safety aspects of X-ray machines, emphasizing proper handling, minimizing radiation exposure, and compliance with safety regulations and monitoring requirements.

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Phil Zarrow

Phil Zarrow is the president and principal consultant at ITM Consulting. With over fifty years of experience in PCB fabrication and assembly, he specializes in both through-hole and surface mount technologies. Phil is well-regarded for his knowledge in automated assembly processes, cleaning methods, and particularly in surface mount processes and soldering technologies, which include printing and reflow techniques, as well as Design for Manufacturability.

Throughout his career, he has held significant technical and management positions at Vitronics Corporation, Excellon-Micronetics, Universal Instruments Corporation, and GSS/Array Technology. He possesses extensive hands-on experience and assists clients in setting up and troubleshooting SMT and TH processes. Additionally, he investigates and implements emerging and advanced technologies, equipment, and processes globally.

Phil is co-author of the books Troubleshooting Electronic Assembly and SMT Glossary: Terms and Definitions. He also holds two U.S. patents related to PCB fabrication and assembly processes, as well as audit methodologies.

Gary Korkala Gary Korkala began his career in industrial radiography in 1959 as an x-ray technician at Pittsburgh Des Moines Steel in Baltimore, Maryland, where he used a Cobalt-60 isotope source to inspect welds. He then joined the Westinghouse Nuclear facility in Eddystone, PA, utilizing isotopes and a Van de Graaff linear accelerator. Following that, Gary worked in nondestructive testing sales with U.S. Testing Company and later served as the sales manager for X-Ray Industrial Distributors. In 1980, he founded Security Defense Systems, which was eventually merged into Kodex, Inc. Today, Kodex specializes in manufacturing industrial high-resolution digital X-ray imaging systems that incorporate the latest technology in microfocus and high-energy X-ray sources, flat panel detectors, and fully automated robotic systems for production applications.