Precision is everything - how smartphones are made

scia systems

Three years ago, Dr Michael Zeuner, Matthias Nestler and their colleagues moved into their 30 square metre office in the Technologie Centrum Chemnitz (TCC). Their idea: to produce systems for the high-tech industry. Using ion beam processes, they developed innovative applications and have since undergone astonishing development. Today, their company needs more than 2000 square metres and they will soon be one of the companies with more than 100 employees. We spoke to the two company founders.

What does scia Systems mean?
It's an artificial name, borrowed from the planning language Esperanto. We didn't want to name the company after a specific person. "scio" stands for knowledge.

You use your knowledge to develop high-tech systems. Who are your customers?
Our customers are producers of components in the microelectronics industry or manufacturers of special optics. Qorvo, for example, is a major customer as one of the most important manufacturers of passive components in mobile communications, or companies from the Carl Zeiss Group that manufacture special optics for the production of integrated circuits. For example, every mobile phone contains components that have been manufactured in stages on our systems. We also work for the hard disc manufacturer Western Digital, for example.

So you operate in an international market?
We realise 80 percent of our business abroad, a large proportion of which is in the USA. There are very specialised companies in the microelectronics sector and there are few companies in the world that can do exactly what we do.

What can your machines do?
It's actually difficult to describe for the general public. Our systems are suitable for manufacturing different products, similar to a CNC machining centre. For example, our systems are used to manufacture frequency filters for mobile communications or position sensors for the automotive industry. The use of the system for a specific production step is the responsibility of our customer, as with the CNC machining centre.
We currently manufacture around ten different products that are used for processes on various components. However, two things are always essential: The systems are always used for the deposition or structuring of demanding thin layers. These can no longer be processed using conventional processes; instead, we utilise vacuum technologies. We can remove small amounts of material in a targeted manner, almost individual atoms. For selected applications, structures must have an extremely precise layer thickness or a precisely defined geometry. Our systems can correct even the smallest deviations with the utmost precision.

At scia Systems, the entire design, control system and software are developed for the systems. The systems are then assembled and commissioned at the Chemnitz Technology Centre using components purchased from subcontractors. After around six. 6 months, delivery is made to the customer. There, engineers then supervise the complete integration into the customer's production process.scia Systems uses a production facility under clean room conditions for system assembly. "Customers can see straight away that the work here is done professionally," explains Dr Michael Zeuner as he puts on his hairnet and cleanroom clothing. "As the components are manufactured in a cleanroom environment, the machine also has to be assembled under these conditions," he explains. It is mainly physicists and electrical engineers who work on the red and white machines, which are similar in complexity to a car. The only difference is that a system is worth one to two million euros," explains the physicist. Overall, the company now has an annual turnover well into the double-digit millions, making it one of the larger companies in Chemnitz in terms of turnover.

How did you come up with the idea of developing such machines?
Ultimately, we were just following technological trends. In the last 10 years, mobile communications in particular have dramatically changed microelectronics. Since the advent of smartphones, new circuits with new sophisticated functionalities have been mass-produced. This has resulted in enquiries from customers asking how we can support their product and technology development. Of course, we have a basic knowledge of the relevant processes and technologies. But today, nobody can think up new products in the quiet of their own home; after all, we always arrive at the final specification of a system in discussion with the customer. And in order to fulfil these customer requirements, constructive cooperation between designers, technologists and programmers is always necessary. This is the key to success in technical industries today.

How did you get started three years ago?
We started here at the TCC with a small amount of space and were then able to expand quickly and flexibly. We now also rent space outside the TCC. An important point in the start-up phase was that VON ARDENNE GmbH, a manufacturer of vacuum coating systems from Dresden, took a half share in scia Systems, which enabled us to secure start-up financing.

Was there also a personal reason for you to set up your own business?
We were convinced that we could achieve something new together, so the focus was less on the individual. We wanted to combine individual expertise into joint ideas. We have undoubtedly succeeded in this. Nevertheless, it was of course also a big step for our own development to take responsibility for the colleagues we now work with.

Was there a particular reason for setting up in Chemnitz?
The choice of Chemnitz was not arbitrary. We all come from the Chemnitz area and so the decision could not be made in favour of any other location. We were also able to recruit specialised staff regionally. We also know that the people here are down-to-earth and loyal. A third of our suppliers also come from the region.

How important is research and development for you?
Ten people work in our development department, all physicists. We operate our own versions of our systems and work on qualifying them for new processes and new customers. In terms of development, you are focussing primarily on new functionalities and new applications.

The two scientists confirm that finding employees has not been a problem so far. The proximity to Chemnitz University of Technology and the university in Zwickau has often paid off. "We once took on four students in one academic year," they say. Nevertheless, you have to give people time to familiarise themselves with the job. Only after a year are they really fit to manage their own projects. They are currently looking for more employees in sales, project management and electrical project planning.

Do you have to encourage the people of Chemnitz?
We do have the impression that the people of Chemnitz are hiding their light under a bushel. With its history and achievements, Chemnitz has nothing to hide. However, we must actually encourage all East Germans that they can achieve something themselves. A little more self-confidence would be good for the whole region.