Delta In-Line Press-Fit Machine and Bottom Router Machine
Accelerate New Product Introduction for Network Switch Manufacturers

As the demand for AI, cloud, and edge computing applications surges, the need for real-time data processing continues to increase, fueling demands for high-bandwidth, low-latency, and reliable network switches. As a critical component of communication infrastructure, switches require high quality and fast time-to-market to support applications like AI servers and mission-critical workloads. When fulfilling low-volume and high-mix production demands, switch manufacturers often face challenges in controlling quality and maintaining production efficiency. To address these pain points, Delta has introduced an automation solution to ensure precision, flexibility, and enhanced productivity.

Delta successfully deployed its In-Line Press-Fit Machine and Bottom Router Machine, forming a tailored automation solution that empowered a leading U.S.-based switch manufacturer to establish a high-end 800G switch production line. The printed circuit board assembly (PCBA) is the computing heart of network switches, integrating resistors, capacitors, ICs, and other components, with assembly quality directly impacting signal integrity and system reliability. Traditionally relying on manual crimping, these processes risked misalignment, uneven pressure, and stress-induced damage, leading to quality inconsistencies. Delta’s advanced automation solution addresses these challenges by enhancing manufacturing flexibility, yield rates, and overall production efficiency.

The In-Line Press-Fit Machine leverages smart PID precision force control and an advanced visual system to deliver micron-level crimping accuracy. The machine also features a dynamic frame limit function to detect bent pins and offers automated operations for loading, fixture changing, and inspection. Its defect detection module captures force variations as minute as 0.1N to ensure quality. With a recipe system storing over 1,000 production profiles, the machine excels in handling diverse, low-volume productions. A detailed recording of process data provides a production history, with data storage of up to 2,000 records per second. This large, comprehensive amount of data helps users in curve monitoring, data tracking, and analysis.

The Bottom Router Machine is engineered for circuit board cutting, featuring a real-time monitoring system that extends cutting tool’s lifecycle and maintains consistent quality. Supporting Gerber file offline programming and fixture-free cutting, it accelerates new product integration. Also, the machine is fully compliant with the IPC-CFX standards and can upload operation data such as critical parameters and alerts to management systems, empowering users to monitor production in real time.

Delta’s In-Line Press-Fit Machine and Bottom Router Machine offer the following benefits:

Flexible Production Line Changeovers  
Over 1,000 recipe profiles and offline programming enable rapid process shifts, addressing low-volume, high-mix needs and accelerating time-to-market.

Enhanced Quality and Yield Rates
Automated crimping and cutting minimize human error, with real-time monitoring and production logs ensuring high quality and superior yield rates.

Data Integration for Smarter Management
Universal communication standards provide real-time data and alerts, while clear visuals help users make smarter decisions faster.

Delta’s innovative automation solution helped the client reduce manual errors in the production process and overcome changeover delays, enabling them to excel in the fast-paced, competitive cloud and data center market.