Lead forming Custom Applications

Tailored Lead‑Forming Solutions for Complex IC Applications

At Fancort Industries, we specialize in custom lead‑forming equipment crafted to tackle the most demanding IC packages—flatpacks, quadpacks, ceramic or metal cans, even optical and oscillating devices. From adjustable progressive tooling and inverted gull‑wing/J‑bend systems to omega bent forms and staggered through‑hole designs, each tool is precision‑engineered for your exact footprint, standoff and production volume. Whether you need one‑off fixtures or semi‑automated progressive line solutions, Fancort engineers tooling that ensures properly formed leads for reliable, defect‑free placement in your robotic soldering process. Discover custom tooling that adapts with your evolving designs—optimizing yield, speeding setup, and ensuring coplanarity every time.

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Adjustable progressive tooling

New!! - Adjustable progressive tooling consisting of individual stations for semiconductor IC strip processing for molded SMTs. Fancort builds and designs dedicated progressive de- dam and de- junk semiconductor tooling. Fancort's new approach allows for maximum flexibility including the capability to repurpose stations for different IC parts.

Tool Die Set #1 - Two station progressive tooling.
Step #1 Interchangeable excise station to remove the frame from each different package type by changing the bottom left-hand plate.
Step #2 - Adjustable corner cutter to remove the corners of a CQFP one corner at a time.

Tool Die set #2 - F-1B/3A standard SMT Fancort tooling.
Step #3 - Adjustable trim tool set the overall lead length and foot length.
Step #4 - Adjustable SMT form and trim , with manual standoff heigh control via custom inserts .

INVERTED GULLWING OR J-BEND tool/s for CFP and CQFPs

Inverted Gullwing or J-BEND Tool/s for CFP and CQFPs

Introducing a revolutionary solution for Inverted gullwing or J bend production. This tooling system consists of a Tool for tie bar removal and another for precision bending. Meticulously crafted to accommodate Flat Packs, Quad Packs, and one-sided TO-220 devices for SMT Inverted Gullwing/J Bend applications, these tools will supply the very best results that are possible for these challenging forming profiles.

EXAMPLE OF THROUGH-HOLE CRYSTAL OSCILLATOR

EXAMPLE OF ONE-SIDED DEVICE THAT HAS BEEN CUT AND FORMED WITH AN OMEGA STYLE BEND

SMT Oscillator

Custom Applications : Custom Lead Forming Applications.

Below are two examples of custom applications that illustrate Fancort capabilities.

We have many more in our 47-year history of designing and building surface-mount lead forming equipment.

Dedicated Progressive Tools for Packages on Lead Frames

Progressive Systems for Packages on Lead Frames

Fancort will design and build progressive tools to process any type of plastic, metal or ceramic package that is produced on a lead frame. The tools are compatible with manual or semi-automatic feeding depending on your budget and production requirements. Progressive trim and form tools, depending on the design, normally consist of from three to five punch and die stations that might incorporate the following operations:

Dejunk of plastic between leads
Removal of dam bars between leads
Cutting of tie bars to set lead length
Final forming to footprint specifications
Singulation of finished device

Tooling holes in the lead frame are used for location by the operator to hand feed from one position to the next. Estimated throughput is 200-400 parts per hour depending on the number of stations used to produce a finished part.

PROGRESSIVE SYSTEMS FOR PACKAGES ON LEAD FRAMES

Fancort latest innovation , adjustable, interchangeable individual tools for low to medium volume progressive de dam and de-junk releasing and forming SMT and thru hole ICs from lead frames .

For the longest time, the only way to remove and process these ICs were in very expensive and long lead time progressive tooling . Fancort have a totally new concept , individual tools that work as a set and achieve the same result. Yes, the biggest advantage is that the tools and be adjusted and or reconfigured for future ICs possibly only change 2 of the step one and step two tools..

A typical multi up lead frame showing an un- molded lead frame that will be required : Excise , de- dam and de-Junk , trim, and form for SMT.

EXAMPLE OF ADJUSTABLE, INTERCHANGEABLE, INDIVIDUAL TOOLS FOR LOW TO MEDIUM VOLUME PROGRESSIVE DE DAM AND DE-JUNK RELEASING AND FORMING SMT AND THRU HOLE ICs FROM LEAD FRAMES

De dam and de junk SMT ICs from their lead frames with

adjustable, interchangeable, and reusable tooling By Fancort Inc. USA.

DIPS TO SMDS

Standard Gull-wing design or optional configurations
Two-stage processing eliminates stress
Consistent standoff control and coplanarity
Process plastic or ceramic packages
Manual feeding
Fits Fancort Model 5000 air press
Optional tube holder for finished parts
Optional track to hold unformed parts
Space grade rad hard parts with an Inverted Gull-wing J type SMT form

P/N D-4 Fixed built-in standoff height
P/N D-4A Adjustable micrometer standoff control. Adjustability is limited by package construction and the standoff tabs on the leads but generally can be .015-.050 “A” on our drawings

Typical DIP to SMT formed in a D-4

TAB EXCISE AND FORM

• Excise and form or excise only
• Ball-bearing die set
• Chrome plating
• Optional loader/unloader
• Fits model 5000L air presses

TO CAN FORMING

TOF-3 form tool with built-in hand press forms to larger bolt circle, square or DIP configuration
Leads can be formed with minimum standoff of .040"
Mechanical lifter to remove formed parts
Comes with prep tool to straighten leads before forming
Cutting of leads before forming can be done on our D-2C machine
TOF-4 with hand press will form and cut radial cans for surface mounting
Plated to prevent rusting

T&F Staggered Through-Hole Custom Applications

TOF-3 form tool with built-in hand press forms to larger bolt circle, square or DIP configuration
Leads can be formed with minimum standoff of .040"
Mechanical lifter to remove formed parts
Comes with prep tool to straighten leads before forming
Cutting of leads before forming can be done on our D-2C machine
TOF-4 with hand press will form and cut radial cans for surface mounting
Plated to prevent rusting

One Stroke Trim and Stagger

Stagger Form and Cut, Two Sides

Flat Packs with a Staggered Form

Staggered Forming Tool to Bend Through-Hole

LEAD TRIM AND FORM EQUIPMENT FOR OPTICAL COMPONENTS

Optical Component Forming

Fancort will design and build trim/form tools for surface-mount or through-hole applications for a wide variety of optical components. We can help you with the design parameters that allow the part to be properly formed with sufficient lead length. These tools are designed to prevent stress to any of the delicate areas, including any glass seals.

Mount die 90 degrees to the front of shoe
Rubber boot to cover springs
Special support to hold fiberoptic cable
Clamps, forms and trims in one operation
Manual standoff control with built-in, pressure-free micrometer
Dead stop to prevent over travel
Conforms to Mil std. 2000
Holds tip-to-tip tolerance of +/- .005
Fits Fancort hand or air presses
Optional Tooling for DIP headers with fiberoptic cable
One-year warranty

Quadpack SMD Tooling for Fiberoptic Headers with Cable Part Number F-1A/4FOC

Mounts 90 degrees to the front of the die shoe
Rubber boots to cover springs
Special support to hold fiberoptic cables (not shown)
Clamps, forms and trims in one operation
Manual standoff control with built-in, pressure-free micrometer
Built-in lifter mechanism to remove formed parts
Holds tip-to-tip tolerance of +/- .005
Process all four sides simultaneously
Fits Fancort hand or air presses
Conforms to Mil std. 2000
One-year warranty

OMEGA Style

Omega Bend/Camel Hump Bend Offers superior vibration resistance and thermal expansion characteristics for ceramic or metal cased quad and flat packs.

Fancort has dedicated tools that process these forms in one operation, including adjustment for standoff height.

Hair-Pin Bend An example of a one-sided device that has been cut and formed with an omega bend style.

QFP ROLLER FORM AND TRIMMING TOOLS

Here you will find some QFP ROLLER FORM AND TRIMMING sample toolings

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We can customize to fit your needs, for more information, click on the button or contact:

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Some of our customers

Fancort customers include the following NASA engineering schools: MIT, John Hopkins, JPL, U of NH, MN, NM, TX and AZ. We are also a major supplier to the national labs system: Sandia, Draper, Fermi and Los Alamos.