In the fast-moving world of electronics, efficient heat dissipation is critical. While thermal pads may seem like minor components, they are essential in managing thermal flow across high-performance electronic assemblies.

At APAGCoSyst, we developed a custom automation solution for thermal pad cutting and placement, because no standard system could meet our production requirements.

Here’s how we engineered a solution that goes beyond what the current market offers.

Modern automotive platforms demand high-density electronics, which in turn require effective thermal management. As electronics become more compact and powerful, so does the need for precise thermal pad application.

Our production environment required:

• High-speed and accurate placement of small thermal pads (6×6 mm and 8×8 mm)
• Repeatable cutting from specialized thermal material sheets
• Automated control of placement
• Seamless integration into a continuous production line

After surveying existing systems, it became clear that no such solution existed in the market… So we created one.

APAGCoSyst Automation team designed and implemented an in-house automated solution for placing thermal interface pads with precision and speed. At the center of this innovation is a patented actuator developed by our engineering team, integrated with a pneumatic and mechanical system made for pad manipulation.

• Precision Cutting: Pads are directly cut from thermal material sheets (currently 400×300×(h)1 mm; other on request)
• Efficient Throughput: The system picks and places multiple pads each time, with a production cycle taking approximately 8 seconds for 4 pads
• Rotating Table Setup: Allows material sheets to be swapped without interrupting the process, enabling continuous production.
• Vision-Based Inspection: Each pad placement is checked by a camera to verify location, size, and correct installation.
• Adaptable Design: The system is scalable to different pad sizes and product configurations.

Our 24/7 production demonstrated:

• Consistent pad placement with no damage or misalignment
• Cycle times of ~4 seconds per unit (2 pads)

Thermal pads play a vital role in thermal management of automotive electronics, and automating their placement delivers measurable benefits:

• • Improved consistency and placement accuracy
• • Reduced manual handling
• • Shorter production cycle times
• • Reduced manual handling
• • Higher throughput for mid and high-volume applications

With this new development, APAGCosyst once again displayed their commitment to innovation and efficiency.

Not only did we create a solution that was not available in the market, but it comes at a fraction of the cost of the alternative technologies such as thermal paste dispensing, while displaying a significantly wider process window (less know-how necessary from the user’s side, less process variability, easier control of the result…)

Do you need to solve your thermal material challenge? Contact us today! We will be happy to customize our solution to your specific material and production need.