0201 and 01005 Adoption in Industry

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INTRODUCTION

First introduced in the year 2000, the 0201 package was sold in significant numbers in the electronics industry by 2003. According to some estimates, it currently accounts for approximately 20% of surface mounted component (SMC) demand worldwide1 . This puts consumption between 100 and 200 billion units per year. Despite these impressive numbers, the 0201 package and its’ smaller cousin, the 01005 package, have not yet achieved anything resembling widespread adoption in the overall electronics industry.

Pioneered for applications where volumetric efficiency is paramount, 0201 and 01005 components have been adopted in many mobile applications and, in limited form, in specific defense applications. Issues related to the extremely small package size have limited wider scale adoption.

The 0201 package measures 0.024” by 0.012” or 0.6 mm by 0.3 mm and is equivalent to the metric 0603 package. The 01005 package measures 0.016” by 0.008” or 0.4 mm by 0.2 mm and is equivalent to the metric 0402 package (See Figure 1). By comparison, a human hair is approximately 0.1mm wide. This miniscule size leads to myriad issues involving manufacturability.

fig 1-13

Many companies report difficulty in finding assemblers capable of reliably placing 0201 and 01005 components. Problems with misplacement appear to be somewhat common. Another issue is the difficulty of visually inspecting these components since inspection requires use of sophisticated optical or x-ray microscopy.

DfR Solutions, in collaboration with Paumanok Group, performed a literature search, market research, and a survey of more than 100 people across the electronics industry in order to understand the adoption, use, understanding, and reliability of 0201 and 01005 components.

MARKET RESEARCH AND LITERATURE ASSESSMENT

A thorough assessment was made of the current state of the market for 0201 multilayer chip capacitors (MLCCs) through publicly available information and literature.

Market Consumption

0201 and 01005 MLCCs are primarily consumed in modules for space-constrained end products. In 2010, the largest markets for these components were power amplifier and radio frequency modules for wireless handsets followed by the defense circuit sector. 0201 and 01005 MLCCs were also used to a much lesser degree in hearing aids. A breakdown of global consumption of 0201 MLCCs in 2010 is below in Figure 2. FR4 Modules are comprised of power amplifier and RF modules for handsets; while, Low Temperature Cofired Ceramic (LTCC) modules are comprised of RF antenna and defense circuitry.

fig 2-11

Market Volume

According to several estimates from major capacitor manufacturers, market volume for 0201 MLCCs is projected to be between 100 and 200 billion units in 2010. When actual manufacturing volumes are investigated from the major 0201 MLCC manufacturers, this can be further refined to 105 to 205 billion units. The most likely number is approximately 178 billion units, or 15 to 20 percent of the global MLCC market. At an estimated price of US$0.0085 per unit (though some units are sold for as much as US$0.025), this puts the size of the 0201 MLCC market at US$1.51 billion.

Performance

0201 MLCCs were sold in NP0, X7R, X5R, Y5V, and X6S performance types in 2010. Estimates for the volumes of each type are shown below in Figure 3.

fig 3-8

Reliability

The large volume of the 0201 market and the development of the 01005 market appear to attest to a certain basic reliability in 0201 components. One vendor has claimed that 0201 components are actually more reliable than larger MLCCs using thousands of layers in high capacitance applications.

SURVEY

A survey was sent to a cross-section of potential users across the electronics industry. It asked a wide range of questions about adoption of 0201 and 01005 components, validation and usage, and attitudes about reliability. The survey flow is outlined in Appendix A and the actual questions are in Appendix B.

102 responses were received from 14 major industry sectors including automotive, military, aerospace, mobile communications, and utilities.

Selected Survey Results – Results in % of Total Respondents

Figures 4-8 show a selection of responses to five of the more demonstrative questions asked in the survey. Some of the comments sent by respondents are also discussed in Section 4 below.

fig 4-6-1

fig 7-8

DISCUSSION

The survey and research performed allowed a certain amount of insight into 0201 and 01005 components and how they are currently used in the electronics industry.

Despite the fact that 0201 components are used in significant volumes, the high usage applications are concentrated in ultra small modules and in high frequency and microwave applications. As noted above, the single largest market for 0201 components is in modules for wireless handsets. So, despite the high volume of 0201 components produced in 2010, the components are actually used by a small percentage of companies in very high volume niches.

It is not surprising that the majority of respondents indicated they are not yet using 0201 or 01005 components. As a whole, the survey population is more conservative in adopting new technologies, preferring to let other sectors resolve infant mortality and reliability issues in “next generation” technologies. However, the actual factors limiting more widespread adoption of 0201 and 01005s were overwhelmingly reported as design, manufacturability, and quality rather than reliability.

One third of survey respondents indicated usage of 0201 components. Approximately 7% of these respondents indicated that they also use 01005 components. Considering the limited market penetration of 0201 and 01005 components and the high reliability needs of the respondents, this is a significant percentage.

Most respondents felt that the reliability was as good or better than parts currently in use. So, reliability concern is not a primary limiting factor. However, some respondents were still concerned about the relative lack of reliability data on these components. 30% of the survey takers do expect to be using 0201’s within three years as design drives the need for these small components. These users are highly concerned about the ability to successfully place and inspect these small components.

The survey response comments indicated some universal concerns and some very specific industry and design specific (see Table 1).

table 1-2

Survey respondents also mentioned the key limiting and driving technical factors in adoption of 0201 and 01005 components (Table 2). Driving factors were primarily related to the benefits of compactness in certain applications, with some respondents also noting the reduced parasitism in small components. Limiting technical factors centered around the limits and difficulties faced by the small sizes, the increased cost of buying and using these components, and the relative scarcity of reliability data on these small components.

table 2-3

CONCLUSIONS

0201 and 01005 components have grown to represent a large portion of the modern component market and will continue to increase as time goes on. Currently, issues with manufacturability, cost of use, and inspection limit wider adoption of these components. The trend for smaller products in certain industries will drive an increase in adoption that will necessarily result in improved practices in manufacturing. As the market matures, and more reliability data becomes available, even those applications where reliability is paramount will begin to see adoption of these small parts. Indeed, the majority of respondents to DfR Solutions’ survey expect to be using 0201 components within the next three years.

Appendix 1: Survey Flow

app 1

Appendix 2: Survey Questions

Adoption of 0201 and 01005 Components in Industry

Thank you for filling out our survey on the adoption of 0201 and 01005 components in industry. All participants will get a copy of the survey results when it is complete.

Participant Information

Tell us about yourself or your company.

What is your email address? *

This information will not be shared.

What is your name?

This information is optional, and will not be shared.

What is the name of your company?

This information is optional, and will not be shared.

Product Line Information

Please tell us a little about one of your company's product lines. Please focus on one specific product line. We encourage you to fill out this survey multiple times for different product lines.

What type of product line is this?

Please choose the option that best fits your product line. Please choose only one of your company's product lines for this survey.

  • Appliances
  • Automotive - Safety
  • Automotive - Under-Hood
  • Automotive - Other
  • Avionics - Commercial/Military
  • Computer - Business
  • Computer - Consumer
  • Computer - Server
  • Computer - Storage
  • Computer - Other
  • Consumer Electronics
  • HVAC
  • Industrial Control
  • Lighting
  • Military - Missiles
  • Military - Other
  • Mobile - Consumer
  • Mobile - Industrial
  • Networking
  • Power - Distribution
  • Power - Monitoring/Metering
  • Power - Solar
  • Rail Transportation
  • Space Systems
  • Test Equipment
  • Utilities - Distribution
  • Utilities - Monitoring/Metering
  • Utilities - Other
  • Other

Product Lifetime Information

What is the desired lifetime of your product line?

Enter the desired lifetime in years.

What is the desired End-Of-Life reliability for your product?

Enter the desired EOL reliability in %.

0201/01005 Component Usage

Does this product line have 0201 or 01005 components? *

  • 0201
  • 01005
  • Both
  • Neither

0201 Capacitor Usage

Do you use 0201 capacitors? *

  • Yes
  • No

0201 Capacitor Reliability

Did you perform any additional qualification activities before accepting 0201 capacitors into your design?

Please select all relevant activities.

  • No additional activities.
  • Aging Studies (i.e. drift).
  • HTOL (not to failure)
  • HTOL (to failure)
  • Manufacturing Process Qualification
  • Ongoing Screening / Auditing
  • Parametric Measurements (capacitance, resistance, inductance, etc.)
  • Supplier Quality Audit
  • Supplier Technical Audit
  • Temperature/Humidity/Bias (not to failure)
  • Temperature/Humidity/Bias (to failure)
  • Other:

Do you believe that 0201 capacitors are more or less reliable than 0402 capacitors?

app 2 form-146961-edited.png

0201 Resistor Usage

Do you use 0201 resistors? *

  • Yes
  • No

0201 Resistor Reliability

Did you perform any additional qualification activities before accepting 0201 resistors into your design?

Please select all relevant activities.

  • No additional activities.
  • Aging Studies (i.e. drift).
  • HTOL (not to failure)
  • HTOL (to failure)
  • Manufacturing Process Qualification
  • Ongoing Screening / Auditing
  • Parametric Measurements (capacitance, resistance, inductance, etc.)
  • Supplier Quality Audit
  • Supplier Technical Audit
  • Temperature/Humidity/Bias (not to failure)
  • Temperature/Humidity/Bias (to failure)
  • Other:

Do you believe that 0201 resistors are more or less reliable than 0402 resistors?

app 2 form-146961-edited

0201 Inductor Usage

Do you use 0201 inductors? *

  • Yes
  • No

0201 Inductor Reliability

Did you perform any additional qualification activities before accepting 0201 inductors into your design?

Please select all relevant activities.

  • No additional activities.
  • Aging Studies (i.e. drift).
  • HTOL (not to failure)
  • HTOL (to failure)
  • Manufacturing Process Qualification
  • Ongoing Screening / Auditing
  • Parametric Measurements (capacitance, resistance, inductance, etc.)
  • Supplier Quality Audit
  • Supplier Technical Audit
  • Temperature/Humidity/Bias (not to failure)
  • Temperature/Humidity/Bias (to failure)
  • Other:

Do you believe that 0201 inductors are more or less reliable than 0402 resistors?

app 2 form-146961-edited

Planned 01005 Component Usage

Do plan to use 01005 components in your product line within the next 3 years? *

  • Yes
  • No

What 01005 components do you plan to use in this product line?

Please check all that apply.

  • Capacitors
  • Resistors
  • Inductors

0201 Usage

Do you plan on increasing the number of 0201 components in the next generation of your product line?

  • Yes
  • No

If 0201 components were not necessary to your application, would you use 0402 components instead? *

  • Yes
  • No
  • 0201 components are not necessary to my application.

01005 Capacitor Usage

Do you use 01005 capacitors? *

  • Yes
  • No

01005 Capacitor Reliability

Did you perform any additional qualification activities before accepting 01005 capacitors into your design?

Please select all relevant activities.

  • No additional activities.
  • Aging Studies (i.e. drift).
  • HTOL (not to failure)
  • HTOL (to failure)
  • Manufacturing Process Qualification
  • Ongoing Screening / Auditing
  • Parametric Measurements (capacitance, resistance, inductance, etc.)
  • Supplier Quality Audit
  • Supplier Technical Audit
  • Temperature/Humidity/Bias (not to failure)
  • Temperature/Humidity/Bias (to failure)
  • Other:

Do you believe that 01005 capacitors are more or less reliable than 0201 capacitors?

app 2 form-146961-edited

01005 Resistor Usage

Do you use 01005 resistors? *

  • Yes
  • No

01005 Resistor Reliability

Did you perform any additional qualification activities before accepting 01005 resistors into your design?

Please select all relevant activities.

  • No additional activities.
  • Aging Studies (i.e. drift).
  • HTOL (not to failure)
  • HTOL (to failure)
  • Manufacturing Process Qualification
  • Ongoing Screening / Auditing
  • Parametric Measurements (capacitance, resistance, inductance, etc.)
  • Supplier Quality Audit
  • Supplier Technical Audit
  • Temperature/Humidity/Bias (not to failure)
  • Temperature/Humidity/Bias (to failure)
  • Other:

Do you believe that 01005 resistors are more or less reliable than 0201 resistors?

app 2 form-146961-edited

01005 Inductor Usage

Do you use 01005 inductors? *

  • Yes
  • No

01005 Inductor Reliability

Did you perform any additional qualification activities before accepting 01005 resistors into your design?

Please select all relevant activities.

  • No additional activities.
  • Aging Studies (i.e. drift).
  • HTOL (not to failure)
  • HTOL (to failure)
  • Manufacturing Process Qualification
  • Ongoing Screening / Auditing
  • Parametric Measurements (capacitance, resistance, inductance, etc.)
  • Supplier Quality Audit
  • Supplier Technical Audit
  • Temperature/Humidity/Bias (not to failure)
  • Temperature/Humidity/Bias (to failure)
  • Other:

Do you believe that 01005 inductors are more or less reliable than 0201 inductors?

app 2 form-146961-edited

01005 Usage

Do you plan on increasing the number of 01005 components in the next generation of your product line?

  • Yes
  • No

If 01005 components were not necessary to your application, would you use 0201 components instead? *

  • Yes
  • No
  • 01005 components are not necessary to my product line.

No 01005 Components

Why do you not use 01005 components in your product line?

Choose all that apply.

  • The product line does not require components that small.
  • 01005 components are too expensive.
  • 01005 components do not have the reliability my product line requires.

Do you have any comments on the subject of 0201 or 01005 components that you would like to share? *

  • Yes
  • No

Planned 0201 Component Usage

Do plan to use 0201 components in your product line within the next 3 years? *

  • Yes
  • No

What type of 0201 components do you plan to use in your product line?

Please check all that apply.

  • Capacitors
  • Resistors
  • Inductors

Do you have any comments on the subject of 0201 or 01005 components that you would like to share? *

  • Yes
  • No

No 0201 or 01005 Components

Why do you not use 0201 or 01005 components in your product line?

Choose all that apply.

  • The product line does not require components that small.
  • 0201 and 01005 components are too expensive.
  • 0201 and 01005 components do not have the reliability my product line requires.

Comments

Do you have any comments on the subject of 0201 or 01005 components that you would like to share?

Submit

Please press submit below. Your survey has not been sent yet. Thank you for participating.

References

 1.) Assessing The World Market For The 0201 MLCC, Paumanok Publications, 2010.

 Disclaimer

DfR represents that a reasonable effort has been made to ensure the accuracy and reliability of the information within this report. However, DfR Solutions makes no warranty, both express and implied, concerning the content of this report, including, but not limited to the existence of any latent or patent defects, merchantability, and/or fitness for a particular use. DfR will not be liable for loss of use, revenue, profit, or any special, incidental, or consequential damages arising out of, connected with, or resulting from, the information presented within this report.

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Best Regards,
Dr. Craig Hillman, CEO