Why ESD protection is still one of the most important elements in modern electronics production

ESD – electrostatic discharge – is far from a new problem in the electronics industry. Yet experience shows that ESD remains one of the most frequent causes of both internal production defects and latent defects that only become apparent after extended use by customers.

Most electronics manufacturers already work in controlled environments and measure ground connections as a natural part of everyday life. But even small deviations in layout, behavior, or equipment can create invisible and critical damage to modern components.

This blog gives you a comprehensive overview of why ESD is still a real risk, what the standards require – and how you can strengthen your ESD setup in practice.

Why ESD still causes problems – even when you “have it under control”

ESD occurs when two objects with different charges touch each other. In a production line, it is typically an operator, tool or surface that hits an unprotected IC pin, pad or printed circuit board.

The dangerous thing is that humans can only feel discharges around 3,000 volts.
Modern electronics can be damaged in a few hundred.

Therefore, ESD can occur:

• without sound
• without spark
• without anyone noticing

...and yet result in:

• catastrophic failures
• latent defects , which only become apparent after weeks or months

Latent errors in particular are costly because they trigger RMA cases, breakdowns and loss of customer trust.

Tighter standards – and greater demands from customers

IEC/DS/EN 61340-5-1 is the main guideline for establishing and maintaining an ESD controlled area (EPA). The standard includes, among other things:

• floors and furnishings with documented dissipation capacity
• ESD-approved clothing, shoes, wrist straps and heel grounders
• ESD-safe tools, table accessories and packaging
• ionization of insulators
• ongoing tests, measurements and documentation

Many customers – especially within medical, automotive, telecom and aerospace – today expect full documentation of ESD control as part of their auditing.

This means that ESD is not only about quality – but also about competitiveness.

The hidden costs of inadequate ESD control

Many ESD-related problems are never registered as “ESD errors.” Instead, they show up as:

• multiple errors in final test
• increased rework
• unstable components
• unexplained errors in the customer's equipment
• expensive RMA cases and support work

The real price of one damaged component can be far higher than the component's own value.

How to build strong ESD control

An effective ESD program consists of three main areas:

1. Interior design – the working environment must provide safe distraction

A stable EPA area requires, among other things:

• ESD floors (e.g. STO)
• ESD table mats and table coverings (e.g. Desco)
• antistatic fixtures from Treston, DESCO, BSC and others.
• ESD-safe magnifying lamps, extraction and PCB holders (e.g. Weller, Alsident)

Many problems arise when replacing fixtures with “non-ESD approved” solutions – even small changes make a difference.

2. Person control – the most important factor

The operator is often the biggest source of static electricity. Therefore, you should always use:

• ESD shoes or sandals (Birkenstock, Sievi)
• wristbands and spiral leads (Desco, BSC)
• ESD-approved clothing with woven conductive fibers
• heel earthers for guests

Regular personal checks with ESD testers are part of the standard.

3. Process control – measurements, ionization and packaging

Even in perfect environments, charges arise on insulators, which is why ionization is necessary.

Recommendations:

• ION fans
• Kapton and antistatic tape
• antistatic bags and MBB bags (Desco, BSC)
• earthing boxes and connecting cables

When the entire chain works, the error rate drops significantly.

Free webinars: get help from the experts

Several major manufacturers – including Desco – offer ongoing free webinars and online training , where they review:

• how to implement IEC/DS/EN 61340-5-1 correctly
• typical errors in EPA areas
• best practices for measurements, material selection and documentation

It is an obvious opportunity for both new and experienced ESD managers, and many companies experience concrete improvements from participating.

Sign up for the HIN newsletter, click on ESD, and receive a direct invitation to these free webinars.

ESD protection is an investment, not an expense

Companies with strong ESD controls experience:

• fewer internal errors
• faster debugging
• strengthened customer confidence
  

That's why ESD protection pays off – both technically and financially.

Do you need sparring?

At HIN, we work with a wide selection of ESD-safe products from Desco, Treston, Weller, BSC, Artigo, Alsident, UIR, Ideal-Tek and others – from floors and mats to tools, clothing, packaging and ionization.

Brian Nielsen is happy to advise and has extensive experience with ESD measurements at customers' premises – where most people are surprised by the charges he finds.

Contact:
📞 +45 31 41 51 52
📧 bn@hin.dk