Special Projects, Special Attention

By Tony Musall

Foresite’s problem-solving technicians take on a new project.





A long-time client approached Foresite about a special project to measure the laser kerf on precision-trimmed resistors. Initial attempts to visualize the kerf via x-ray were ineffective. Ultimately, Foresite developed a chemical removal process for the glass epoxy to expose the laser kerf for high-magnification measurement on the Keyence VHX-5000 digital microscope. The resulting images and measurements confirmed that a manufacturing issue was the root cause of the client’s concern.


Screen Shot 2019-07-02 at 10.54.30 AM Screen Shot 2019-07-02 at 10.54.38 AM

Figures 1 and 2: Component as received, and component after epoxy removal

At Foresite, we pride ourselves on being more than an analytical laboratory that produces data. We strive to employ all our tools and knowledge to provide root-cause determination and actionable advice to solve real-world problems. This includes on-site process audits offered globally and on-site testing, cleaning, and recovery services.


To that end, we occasionally receive requests from clients with unique challenges or opportunities that would fall outside the realm of a typical analytical laboratories’ comfort zone.  Foresite’s technical staff has a diverse background—including automotive, aerospace, integrated circuit layout and testing, new product introduction, warranty analysis, manufacturing support, and test design—but they all share the trait of being effective problem-solvers.


Foresite’s capabilities extend far beyond determining cleanliness of electronic assemblies. Expand your engineering resources and let us use our unique combination of experience, knowledge, and equipment to help you quickly and effectively institute a test plan, evaluation, or root-cause analysis.

  • Inline aqueous cleaning system
  • Plasma oven
  • Inline reflow oven
  • Pace IR reflow system
  • High-magnification imaging (Visual/SEM)
  • Low volume conformal coating
  • Design/Layout/DfM consulting
  • World-class cross-sectioning capabilities
  • Conformal coating removal (chemical / mechanical)

About the author

Tony Musall, who was previously with Delphi Electronics, has been with Foresite for almost seven years as a project engineer. He specializes in failure analysis techniques, utilizing ion chromatography, FTIR, XRF and X-ray. He advocates problem solving specific to client issues.



Have questions? We would love to help. Contact Foresite, Inc. today to discuss how we can help you figure out your electronics reliability issue.

Contact Us