Process overview

1. Parts Preparation
2. Laminating and Coating Hydrophobic Film
3. Cartridge Assembly
4. Testing
5. Packaging

1. Parts Preparation

ID	1.1.
Title	Top Cover Preparation
Scope	Prepare the top cover with adhesive tape for assembly

Materials

• Top cover
• Kapton tape, 80 um, double sided silicon adhesive

Step-by-step

1. Remove liner from double sided kapton tape and apply it to a non sticking cutting mat
2. Cut out kapton stickers using USB desktop cutter. File can be sent by smart phone app (fig 1)
3. Apply kapton sticker to top cover using the cartridge alignment jig. First lay down the sticker with the sticky side up then the cover. (fig 2)
4. Pass the top cover through a laminator (fig 3)
5. Score the peel-off tap with a sharp knife close to the edge of the cover (fig 4)
6. Remove the kapton from the peel-off tab (fig 5)

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ID	1.2.
Title	Spacer Frame Preparation
Scope	Prepare the space frame with adhesive tape for assembly
Buy	Shop link for Spacer Frames

Materials

• Spacer frame
• 278um 3M PET Membrane Switch Spacer with double sided acrylic adhesive (7961MP)

Step-by-step

1. Cut out spacer using laser cutter. (fig 1)
2. Apply spacer sticker to spacer frame using the cartridge alignment jig. First lay down the sticker with the sticky side up then the frame. (fig 2)
3. Pass through the laminator

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ID	1.3.
Title	Electrode Board Preparation
Scope	Prepare the electrode board with double sided adhesive masking for laminating

Materials

• Electrode baoard (shop link)
• Kapton tape, 80 um, double sided silicon adhesive

Step-by-step

1. Remove liner from double sided kapton tape and apply it to a non sticking cutting mat
2. Cut out kapton stickers using USB desktop cutter. File can be sent by smart phone app (fig 1)
3. Apply kapton sticker to electrode board by aligning it as shown in fig. 2
4. Pass electrode board through a laminator

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ID	1.4.
Title	ITO Glass Coating
Scope	Hydrophobic Coating of the ITO top cover glass

Materials

• Conductive (ITO coated) top cover glass (shop link)
• Cytonix, Fluoropel coating – PFC1601V-FS

Step-by-step

1. Using a multimeter test for the conductive side. (fig 1)
2. Put the glass with the conductive side facing up on a spin-coater (with vacuum chuck)
3. Apply 60 ul of Fluoropel coating using a micro pipette (fig 2)
4. Spread the Fluoropel using a plastic squeegee over the full size of the slide (fig 3).
5. Spin slide at 2500 rpm for 30 seconds
6. Cure on hotplate at 180°C for 20 minutes (fig 4)

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