The Essentials of ESD Control

Electrostatic discharge happens when two objects that have different potentials transfer their electrical charge, usually through close proximity or direct contact. Static electricity can build up in many common manufacturing and laboratory scenarios, from manipulating components to normal contact between materials. 

Preventing ESD damage is critical when working with sensitive electronic parts, such as semiconductor chips and integrated circuits. As demand for electronics increases, so does the need for effective and affordable ESD control solutions in a variety of industries. 

What Is ESD Control and What Does It Involve?

Any approach to prevent or reduce electrostatic discharge is technically a form of ESD control, including designing electronic components with static-dissipative materials. More commonly, ESD control refers to manufacturing practices, systems, station layout, workplace materials, and product packaging that are designed to prevent or minimize ESD risks.

To understand how ESD control works, it’s first necessary to know the causes of static electricity issues. Insulating materials promote electrostatic buildup because they prevent a component’s charge from normalizing through harmless grounding. Standard plastics can have this effect, which is why electronics parts manufacturers look for product packaging with antistatic properties or coatings.

Humidity problems and equipment that creates an electrical field also contribute to ESD. Control measures require educating workers on the correct usage of equipment, such as mixers, centrifuges, and laboratory analysis systems.

ESD control also includes implementing strategies for the elimination of electrostatic buildup. This is why workers who handle sensitive components must use grounding straps. Conductive materials naturally help neutralize static electricity when they are properly grounded.

What Types of ESD Control Products Do Manufacturers Need?

For workspaces, antistatic flooring and correctly engineered grounding of contact surfaces help to dissipate electrical charges. Employees must also wear appropriate clothing, such as ESD shoes, antistatic cleanroom gloves, or wrist straps.

ESD control products can simplify and improve electronics manufacturing. There are antistatic, dissipative, and conductive versions of many items necessary for production.

ESD Control Bags

ESD-safe bags are effective for inter-facility transportation and packaging of end components. Different options provide increased levels of antistatic protection:

• Antistatic bags
• Static dissipative bags
• Conductive bags for ESDS grounding
• Shielding bags

Metallized shielding bags can dissipate external buildup, protecting sensitive components against ESD, similar to the effect of a Faraday cage. Other antistatic bags are designed to reduce static buildup inside or actively shunt static charges away from sensitive electronic components.

ESD Control Packaging and Containers

Many electronic components and semiconductors require protection against physical impacts and thermal shocks in addition to static buildup and ESD. In these cases, ESD-safe plastic trays are an ideal solution.

Packaging for ESD control often uses:

• Conductive ABS
• Blue antistatic HDPE
• Antistatic polycarbonate
• Antistatic PVC
• Antistatic PET

The wide variety of options available allows for detailed tray customization based on product and manufacturer needs. The shape, size, strength, and conductivity of materials are all variable.

Why Is ESD Control Important?

ESD control plays an important role in every aspect of electronics manufacturing, from product creation to distribution. It can directly impact manufacturing costs, product quality, and component longevity.

Protect Sensitive Components

Many electronic and specialized products are sensitive to ESD. Some examples include:

• Integrated circuits
• Electronic control modules
• Low-voltage capacitors
• Semiconductors, such as CPUs, GPUs, and system-on-a-chip architecture
• LEDs and laser diodes
• Optical devices

Uncontrolled ESD can have a variety of negative effects on electronic components. The worst is complete failure, where the electronic part doesn’t work due to catastrophic damage from voltage. But even lower levels of ESD can harm parts, altering key parameters, impacting operating specifications, or reducing the load life of the component and degrading connected systems.

Limit Manufacturing Costs

Independent figures are hard to verify, but some professionals estimate that component loss due to ESD damage may cost the manufacturing industry billions of dollars a year. Some ECMs and ECUs cost thousands to manufacture, so each failure is prohibitively expensive.

Avoid Reputational Damage

Manufacturing defects that occur at a factory are one thing, but damaged components that arrive at a customer’s location can be far more costly, including added transportation costs and shipping delays.

ESD control is part of quality control, and failures impact a company’s reputation. Clients who receive defective goods are likely to seek out other suppliers or manufacturers.

Comply With Regulatory Standards

International standards for some industries require implementing ESD control products and systems:

• ANSI/ESD S20.20 – Standard for the Development of an ESD Control Program
• IEC 61340-5-1 – Protection of Electronic Devices From Electrostatic Phenomena
• JEDEC JESD625B – Requirements for Handling Electrostatic-Discharge-Sensitive (ESDS) Devices

Customers looking for high-value electronic components often request proof of ANSI or IEC compliance. ANSI/ESD S20.20 also replaces MIL-STD-1686 for defense contractors.

Protect Workers and Operating Environments

Electrical buildup in moderate- or high-voltage situations can deliver dangerous shocks to personnel. In laboratories with flammable atmospheres, even a minor spark can trigger ignitions that put workers and equipment in harm’s way. ESD control in these situations requires mitigating static buildup, avoiding insulators and non-authorized packaging materials, controlling compliance, and using conductors with grounding systems.

Which Industries Need ESD Control Products?

Electronics manufacturing is one of the most important areas for ESD control, with direct benefits for profitability, productivity, quality, customer satisfaction, and market growth. In today’s technology-driven world, the reality is that most manufacturing industries need to develop ESD control programs that fit the organization’s scope.

Carmakers rely heavily on electronic control units. Data centers need to protect CPUs, GPUs, network equipment, and optical components. Defense contractors also utilize sensitive components for many systems, from aviation parts to monitoring equipment.

Laboratories need to reduce environmental interference and sparks. Medical device manufacturers work with components that are prohibitively expensive and extremely sensitive to low voltage.

Cost-Effective ESD Control Solutions

The right solution for ESD control depends on manufacturing processes, site layout, and transportation needs. Following workstation best practices can reduce the likelihood of ESD, but proactive control products are essential for protecting sensitive components. Costs are also an important factor for high-volume OEMs.

At Ready-Made Plastic Trays, we help electronics manufacturers find the right balance of cost, durability, and ESD control. Our high-quality antistatic and conductive trays deliver excellent performance, and we offer fully customizable solutions. Request a free sample today.