In 1979, Eagle Electronics began its journey in printed circuit board (PCB) manufacturing, establishing its current site in Schaumburg, IL, near Chicago’s O’Hare Airport in 1985. A major turning point came in 2001 when the company faced a critical decision: close, become a broker, or restructure. Choosing to remodel transformed operations, reducing work-in-progress inventory and reshaping its business.

Now part of Summit Interconnect, which acquired Eagle Electronics in 2021, the Schaumburg site is a key player in Summit's eight-facility network across North America. With 90% of its business coming from the U.S. and additional customers in Malaysia, China, and India, the facility specializes in quick-turn projects with lead times of 24 to 72 hours and medium-volume production.

The pandemic-induced semiconductor shortage caused a surge in orders, but demand has since stabilized. Brett McCoy, vice president and general manager of the Schaumburg site, remarked, “We’re starting to see the effects of that overordering unwind.”

The Schaumburg facility, with its 85-90 employees, produces up to 100 panels per project. Equipped with 42,000 square feet of production space, the site is capable of handling a broad range of technologies. McCoy notes that layer count is no longer an issue, with most projects ranging from 2 to 8 layers, though the facility can manage up to 40 layers if needed.

Schaumburg frequently works on via-in-pad and stacked microvias, employing MacDermid’s Eclipse direct metallization for microvias. The facility also boasts laser drilling capabilities for thin dielectrics and uses advanced equipment such as Orbotech and Schmoll for imaging and AOI, ensuring high-quality production.

McCoy highlights the facility's unusual layout, which mirrors the production process, increasing efficiency. It features advanced routing and drilling capabilities, with the flexibility to manage multiple boards simultaneously.

Summit Chicago offers a range of finishes, including MacDermid immersion silver, Uyemura ENIG, and gold tabs. The facility is fully digital for both inner and outer layers and solder mask imaging, with ongoing investments in tools like MacDermid’s Multibond for multilayer adhesion and TrueChem software for chemical analysis.

Automation and process control are critical to the facility’s operations. McCoy stresses that while technology is essential, automation is the key to improving efficiency and addressing the challenge of finding skilled workers. Summit uses key performance indicators (KPIs) to monitor everything from production throughput to individual operator performance.

Environmental responsibility is also a priority. The Schaumburg site treats 100% of its wastewater onsite and generates its own deionized water, reflecting Summit’s commitment to sustainability.

Looking ahead, McCoy remains optimistic about the future, particularly with government initiatives like the CHIPS Act providing support for U.S. electronics manufacturing. As part of Summit Interconnect, the Schaumburg facility will continue to play a vital role in delivering cutting-edge PCB technology through a focus on automation, quality, and efficiency.