PatchWork® stencils, the laser-cut step stencils

When things get really challenging: PatchWork® stencils

With LaserJob's PatchWork® technology, you can print solder paste deposits of varying heights in a single squeegee operation:

Precise, flexible, and efficient!

Thanks to laser-welded steps made from precision sheet metal (sheet thickness tolerance of +/- 2%), individual requirements for solder paste quantities can be implemented precisely—ideal for every component with a reproducibility of >6 sigma.

Benefit from our many years of experience and rely on maximum flexibility and precision in solder paste printing!

Precise solder paste printing

Production takes place in several steps: First, an opening for the patch is cut out of the base plate using a laser, then the precisely fitting stainless steel plate in the desired thickness is welded in, and finally, the apertures are cut in a single operation. This technology enables precisely defined step heights without manufacturing restrictions and ensures precise, rounded patch edges.

For PCBs with mixed components, changing the amount of solder paste across the aperture area is usually no longer effective. The PatchWork® step stencil solves this problem by changing its sheet thickness. Thicker patches create larger solder paste volumes (step-up) for components such as connector strips or power electronics. Thinner patches create correspondingly smaller solder paste volumes for components with fine-pitch or grid array connections.

Cross-section PatchWork® step Stencil with step-up:

Cross-section PatchWork® step Stencil with step-down:

With PatchWork® technology, even complex requirements such as different solder paste volumes in confined spaces, e.g., in QFP components with heat sink connections, can be met.

A special application of the step template is the patch-in-patch variant. It is always used when different levels within a component mold have to be soldered. One typical example of this is a QFP component with heat sink connections.

Another special application of the PatchWork® technique is the recess on the PCB side (bottom) of the stencil. For this purpose, a thinner sheet metal is welded flush on the squeegee side. This technique is mainly used when identification labels, barcode labels, etc., are already applied to the PCB surface.

Cross-section of a step-down on the stencil's underside:

Sectioning the area where the solder paste height is to be modified
Manufacturing the patch with the appropriate sheet metal thickness
Welding the patch into the base template
Trimming all apertures in a single operation, thereby maintaining the high precision of the template

Advantages of this manufacturing process

rounded step edges due to welding technology + smooth surface = optimal solder paste discharge properties
retrospective insertion of patches, both step-up and step-down, even possible in modified patch thicknesses
express service available starting at 6 hours / ExW
steps have the same fine tolerances as all LaserJob templates

About our know-how

We are pioneers in laser-welded step templates

precisely fitting steps in 10-micrometer increments, material thicknesses from 50 to 500 micrometers possible
exact material thickness with a tolerance of ±2% of the sheet thickness
steps possible on squeegee and circuit board sides
retrospective fitting of steps in SMD stencils and PatchWork® stencils
high repeat accuracy and permanent dimensional stability thanks to precise laser cutting and welding technology
the special manufacturing process ensures clean removal behavior and increased service life

PatchWork® stencil variations

Based on our more than 30 years of experience, we now offer you proven stainless steel sheets with consistent properties:

Stainless Steel 1.4301
Hardness (Hv): min. 370
Tensile Strength (N / mm²): > 1100
Sheet metal thickness tolerance: ± 2 %

We can offer you the following material thicknesses from stock:

PatchWork® stencils in (μm): 20, 30, 40, 50, 60, 70, 80, 90, 100, 120, 130, 140, 150, 180, 200, 250, 300, 400
PatchWork® stencils in the VectorGuard tensioning system in (μm): 80, 100, 120, 130, 150, 180, 200, 250
maximum sheet thickness: 2 mm
maximum working area: 800 x 600 mm

We can offer you your PatchWork® stencils as fixed-frame stencils in frames suitable for your screen or stencil printer:

Aluminium frames
Cast aluminium frames
Stainless steel frames

A wide range of different profiles are also available. Aluminium slope frames, for example, achieve high and reproducible tension values while also supporting reliable cleaning of the frame and stencil surfaces.

All frames can be individually designed with threaded bushings (welded or pressed in).

We use stainless steel screen mesh (80 mesh / wire diameter 0.1 mm) with high tension (> 40N / cm). Of course, the tension can be adjusted to your requirements. A screen filler can be applied on request. This prevents contamination of the printer.

The frames are reusable. We clean them and check them for flatness so that they are ready for immediate use the next time they are needed. On request, we can manage your frame storage at our premises.

In addition to templates in fixed frames, we also offer modern stencils for our

LJ 745 tensioning system

Of course, we also cut the appropriate templates for other quick-clamping systems in the usual LaserJob quality:

PatchWork® stencil post-processing

All laser-cut templates from LaserJob are then brushed. A CNC-controlled brushing process removes the cutting burr on the laser exit side. The brush head moves in a meandering pattern in all four directions across the surface.

Benefits of this post-processing

no enlargement of the apertures
minimum material removal < 2 μm
the narrow material thickness tolerances are maintained.
uniform sheet thickness

Our product range

Why chose LaserJob?

adept knowledge

Through our customized data preparation solutions and the optimization of your CAD data in collaboration with our specialists, we guarantee maximum efficiency and quality for your project.

direct contact

Your immediate access to us: Personal contact – fast, easy, and reliable.

all from one provider

We combine a wide variety of technologies and processes to achieve the best results: cutting, welding, marking, ablating, coating, etc.

express delivery

6-hour express service ex works:
Orders received by 1 pm
shipped on the same working day.

To ensure that your order is processed quickly, please send it to us with your data by email to mail@laserjob.de

We process your data in the following formats: Gerber, ODB++, DWG, DXF, Eagle and IGES/step.

Our delivery times at a glance:

Standard delivery for SMD stencils/PatchWork® stencils:
3 working days from receipt of order (by 5 pm)
Standard delivery for NanoWork® stencils:
4 working days from receipt of order (by 5 pm)
48-hour express service:
Delivery on the next business day (by arrangement, orders received by 5 pm)
24-hour express service:
Next business day delivery (by arrangement, orders received by 5 pm)
6-hour express service ex works:
Same-day delivery (by arrangement, orders received by 1 pm)

Shipping and packaging – Secure, flexible, and environmentally conscious

To ensure that your products arrive safely and in perfect condition, we rely on flexible shipping solutions and well-designed packaging concepts.

Shipping – Fast and tailored to your needs

Daily shipping: We ship your orders daily with DHL Express.
Custom shipping options: Upon request, we may also use UPS, FedEx, DPD, or other shipping providers of your choice.
Diverse transportation options: In addition to traditional parcel services, we offer direct deliveries and courier services with experienced partner companies. This allows us to respond flexibly to your requirements and delivery dates.

Packaging – Safe and sustainable

Eco-friendly packaging: All LaserJob parts are shipped in environmentally friendly cardboard boxes or reusable packaging. This conserves resources and protects the environment.
Safely packed: To prevent damage, all products are carefully wrapped in appropriate packaging – we are also happy to follow your individual specifications.
Special solutions for stencils: We offer special storage bags for our stencils in the tensioning system, which ensure optimum protection and convenient handling.
Customer-specific returnable packaging: Would you like to use your own packaging solutions? No problem! We will gladly assist you in developing and integrating your own returnable packaging into our shipping process.

Put your trust in our experience and flexibility – for shipping that provides optimum protection of your products and focuses on your requirements.

FAQ: Frequently asked questions

With our special cutting and welding process, we automatically create rounded edges in the step area. This allows the squeegee to gently adapt to any height or depth in the template.

The design guideline IPC-7525B (2011) for printing stencils can be ordered directly from IPC.org or from the FED association. If you are unsure, please give us a call! We will be happy to work with you to find individual solutions.

Generally speaking, step differences of up to 3 mm can be achieved with our technology. However, the design recommendations for the printing process should be taken into account, particularly the distances between the steps across the squeegee direction.

As a rule of thumb, for every 25 µm step difference, the distance from the step edge to the aperture in the step should be at least 0.9 mm. This means that for a step difference of 0.1 mm, the distance in the step should be at least 3.6 mm. In practice, however, step differences of more than 80 µm are rarely used in the SMD range.

For large steps, slotted squeegees are used to match the layout. These can be ordered from ourselves together with the stencil.

The standard delivery time is 3 business days. Additionally, 6 and 24-hour express service is available.

Even if the step template has already been used in your production, further modifications to the step height can be made. The requirement is that the template is still in proper condition.

Multiple steps can be created, even with different depths and heights. Steps can also be inserted within other steps.