Category: Air Knife

EXAIR Products in the Semiconductor Industry

Published on by Jordan T ShouseLeave a comment

Manufacturers in semiconductor assembly and PCB production face strict cleanliness, throughput, and thermal-control requirements. EXAIRs compressed-air products, specifically our Air Knives and Vortex Tubes, and air amplifiers are proven, compact, and energy-efficient tools for precise blow-off, controlled cooling and heating for spot thermal conditioning and fume extraction. This Blog explains how EXAIR Super Air Knives and Vortex Tubes and Air Amplifiers address three common production needs: 

  1. Drying and particulate removal during lead frame processing with air knives. 
  1. Localized cooling/heating for functional PCB testing using Vortex Tubes. 
  1. Fume extraction during etching, cleaning and plating processes

I’ll cover technical fit, typical performance characteristics, and measurement/ROI considerations so engineers and plant managers can evaluate and implement these solutions. 

Intellistat Ion Air Nozzle in clean room, cleaning microchip parts before installation.

Super Air Knife and Success in the semiconductor lead frame manufacturing process.  

Typical use cases 

  • Removing rinse water or flux residues after cleaning 
  • Blowing off foreign matter, over spray, or machining debris prior to plating or die bonding. 
  • Drying prior to molding or coating operations. 
  • Static-assisted blow-off when combined with static eliminating product for electrostatically attracted particles. 

Why Super Air Knives? 

  • Uniform Laminar Sheet of air: delivers consistent, even blow-off across the width of a lead frame, reducing localized hot spots or mechanical damage. 
  • Adjustable force and flow: adjusting air pressure and shim size allow you to control force and volume so fragile wires or plated surfaces aren’t damaged. 
  • Entrainment & Efficiency: The knives are engineered so they entrain ambient air, increasing total developed flow and reducing compressed-air consumption compared to open pipes. 

Vortex Tubes for functional PCB testing / burn-in and thermal cycling

During in-line or bench functional testing, specific components or integrated circuits may overheat or require temperature conditioning to verify performance at the full range of the rated temperature specifications. Vortex Tubes give fast, localized cooling (or heating) without coolant loops, chillers, or plumbing intricacy. Subjecting devices to burn-in and thermal cycling stress helps products enter the field with confidence there will not be any preventable failures. Normally, environmental chambers are used for burn-in processes, but vortex tubes can help facilitate localized thermal ramps, corner stressing, or temporary additional cooling/heating when size, cost or availability of a full environmental chamber isn’t feasible.  

Why Vortex Tubes fit testing 

  • Instant cold/hot air from regular compressed air: no refrigeration system or refrigeration cycle; instantaneous on/off.  
  • No moving parts: high reliability and low maintenance for test fixtures. 
  • Local spot conditioning: focus cooling on integrated circuits or other small areas without cooling the entire board or fixture. 
  • Adjustable cold fraction: Vortex tubes can be tuned via the control valve to trade flow vs. temperature drop to meet testing conditions. 
Cooling or Heating with the Vortex Tube

Air Amplifiers for fume extraction and partial heat control during etching, cleaning and plating processes.

In semiconductor lead frame manufacturing, maintaining clean, particle-free environments is essential to ensure consistent product quality and process reliability. Processes such as flux cleaning, plating, molding, and soldering generate vapors, fumes, and fine particulates that can contaminate delicate components or compromise yields. EXAIR’s Super Air Amplifier provides an efficient, quiet, and maintenance-free solution for capturing and removing fumes, vapors, and airborne contaminants from sensitive production areas.

Why the Super Air Amplifier?
High-Volume Airflow Through Amplification

  • It uses a small amount of compressed air to entrain large volumes of ambient air multiplying total flow by up to 25 times.
  • Creates a strong, consistent vacuum draw ideal for capturing fumes and fine particulates at their source.

Energy Efficiency

  • Dramatically reduces compressed-air consumption compared to traditional vacuum or exhaust systems.
  • No electricity, motors, or moving parts, maintenance-free operation and long service life.

Compact and Versatile

  • Easy to integrate above process lines, in tool enclosures, or at conveyor transfer points.
  • Available in aluminum, stainless steel, and high-temperature materials for compatibility with cleanroom or chemical environments.
Model 120024 4″ Super Air Amplifiers are commonly used to exhaust smoke and fumes.

ROI and how to show value quantitatively  

  • Baseline metrics: scrap/rework rate, cycle time, compressed-air consumption, downtime for cleaning, and throughput. 
  • Pilot run: instrument a section of line with flow/force and temperature sensors for a 30 day trial. 
  • Key calculations: 
  • Reduced rework % × cost per part = direct savings. 
  • Throughput increase (parts/hr) × margin = additional revenue. 
  • Compressed-air energy reduction (compared to previous blow-offs) = kW savings (U.S. Department of Energy offers a benchmark of $0.25 per 1,000 SCF). 
  • Tangible benefits: throughput improvement, energy savings, reduced capital cost (vs. chillers/chambers), lower maintenance and smaller footprint. 

Conclusion  

EXAIR Super Air Knives, Vortex Tubes and air amplifiers are compact, reliable, and flexible products that can improve cleanliness, thermal testing, and throughput in semiconductor processes.  

  1. Select a process you think could be helped with an air knife, Vortex Tube or an air amplifier and take advantage of our 30-day money-back guarantee.  
  1. Validate throughput and quality improvements and calculate ROI. 
  1. Rollout with appropriate controls, filtration, and operator training.  

If you think any of our products can help you in your process, please reach out. We have a team of application engineers here M-F to answer your questions!

Jordan Shouse, CCASS

Application Engineer

Send me an email
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EXAIR Super Air Knives and Plumbing Kits

Published on by Jordan T ShouseLeave a comment

When it comes to drying, cooling, or cleaning processes, efficiency and consistency matter. EXAIR’s Super Air Knives are engineered to deliver a uniform sheet of air across the entire length of the knife, making them the ideal choice for a wide range of industrial applications.

Sixteen stock lengths, and Four stock Materials

Why Choose EXAIR Super Air Knives?

The Super Air Knife is designed for energy efficiency, low noise, and powerful performance. By entraining surrounding air at a 40:1 ratio, it amplifies the airflow while minimizing compressed air consumption. This results in:

  • Up to 90% air savings compared to open pipe blowoffs.
  • Quiet operation, typically under 69 dBA—even at 80 PSIG.
  • Uniform airflow across the full length, ensuring even drying and debris removal.
  • Maintenance-free operation with no moving parts to wear out or require adjustment.

These air knives are available in aluminum, 303 and 316 stainless steel, and PVDF, making them suitable for everything from general industrial use to harsh chemical and washdown environments.

Streamlined Installation with Plumbing Kits

To make setup simple, EXAIR offers Plumbing Kits—pre-assembled and ready-to-install packages that include everything you need for optimal performance. Each kit includes:

  • Properly sized fittings and hoses for balanced air distribution
  • Crosses and tees for different length knives
  • Optional kits with filter and regulator assemblies to ensure clean, controlled air supply

Plumbing Kits eliminate the guesswork and ensure your Super Air Knife operates at its best from day one. They also save valuable installation time and guarantee consistent performance across multiple units.

A Complete System for Peak Performance

When combined, EXAIR’s Super Air Knives and Plumbing Kits provide a turnkey solution that delivers:

  • Consistent airflow
  • Simplified setup and maintenance
  • Lower installtion costs
  • Increased productivity and product quality

From drying bottles on a packaging line to removing debris in machining or coating operations, EXAIR’s Super Air Knife system is engineered to outperform traditional blow off methods. Ready to improve efficiency and lower energy costs? Explore EXAIR’s full line of Super Air Knives and Plumbing Kits to find the best setup for your application.

Jordan Shouse, CCASS

Application Engineer

Send me an email
Find us on the Web 

Halloween Blast from the Past: Milling Frozen Human Body

Published on by Tyler DanielLeave a comment

Every now and then, an application comes across our desks that’s a little out of the ordinary. With Halloween around the corner, it felt like the right time to revisit one of the strangest (and certainly most memorable) uses of EXAIR products we’ve ever come across.

Several years ago, a research group reached out with an unusual request. They were involved in a project studying human anatomy through a process that required milling a cadaver and then photographing each layer to build a precise, three-dimensional representation of the body. Each pass removed only about 300 microns of material, meaning that hundreds of layers were milled and documented throughout the process.

For the imaging to be accurate, each freshly milled surface had to be completely clean and evenly prepared before a photo was taken. Any debris or uneven surface finish could distort the final image, and repeating a cut or photo sequence was time-consuming. That’s where EXAIR came in.

To remove dust and debris left behind from the milling process, they incorporated a Stainless Steel Super Air Knife (Model 110012SS). The knife delivers a clean, uniform curtain of air across the surface, removing any residue without physically touching or damaging the material. Immediately following the blowoff, an Atomizing Spray Nozzle (Model EB1020SS) applied a fine mist of isopropyl alcohol across the surface to improve imaging contrast and clarity.

A Stay Set Hose (Model 9212) allowed the nozzle to be positioned precisely where it needed to be and to stay there through long hours of operation. This combination replaced a previous setup that relied on a liquid-only spray, which often left uneven coverage and required rework. With the EXAIR system in place, the team achieved consistent, repeatable preparation of each layer and saved significant time by eliminating variability in their process.

While it’s not every day we see our products used in anatomical research, this one stuck with us. It’s a great example of how compressed air solutions can improve consistency and control in highly specialized applications.

So, in the spirit of the season, we thought it was worth dusting off this story as a reminder that EXAIR products show up in all kinds of places. Whether you’re cooling, cleaning, coating, or even preparing something for a close-up, there’s usually an efficient way to do it with compressed air.

Have an unusual application of your own? We’d love to hear about it. Reach out to an Application Engineer today.

Tyler Daniel, CCASS

Application Engineer

E-mail: TylerDaniel@EXAIR.com

X: @EXAIR_TD

Ask Your Application Engineer If An EXAIR Air Knife Is Right For You

Published on by Russ BowmanLeave a comment

Right on schedule with the change in temperature as summer turns to fall, I woke up with a scratchy throat, runny nose, and a bit of fatigue this morning. I weighed my options for relief in the medicine cabinet: pain reliever/fever reducers, over-the-counter cold & flu medication that add cough suppressants, expectorants, and decongestants to the mix, homeopathic remedies with zinc, echinacea, all natural immune boosters, and a jar of honey for my tea or bourbon, depending on the time of day…and my mood. If my symptoms worsen, I can get tested for the flu or COVID, and may be prescribed antiviral medication. In any case, rest and hydration will likely be important factors in my recovery.

Much like my medicine cabinet, the Air Knives section of the EXAIR catalog has a selection of remedies for problems that can be addressed by a curtain of air. If the curtain of air needed is 36″ or less, we can consider any of the three styles of Air Knife we make: Super, Standard, or Full Flow. If it has to be more than that, the Full Flow Air Knives are out (36″ is their max length) but Standard Air Knives come in lengths up to 48″. Super Air Knives give us the most range here; they come in lengths up to 108″, and can actually be coupled together to provide uninterrupted curtains of flow in whatever length is needed.

Super Air Knives (left) come in lengths up to 108″, Standard Air Knives (middle) up to 48″, and Full Flow Air Knives (right) up to 36″.

Standard and Full Flow Air Knives come in aluminum or 303SS. Aluminum is lightweight and suitable for general purpose applications where high heat and corrosive elements are not a factor. Aluminum Air Knives are rated to 180°F. Type 303 Stainless Steel is suitable for mildly corrosive environments, and is rated to 800°F ambient temperatures.

Super Air Knives are available in aluminum and 303SS, as well as 316SS and PVDF. Type 316 Stainless Steel is stronger and more corrosion resistant than Type 303, and offers superior resistance to certain pitting, which makes it the best choice for food, pharmaceutical, and surgical product manufacturers. PVDF (polyvinylidene fluoride) Super Air Knives have Hastelloy C276 hardware and PTFE Shims. They provide superior corrosion resistance in more aggressive situations than Stainless Steel can like, like in electroplating, solar cell and lithium ion battery manufacturing, strong acid & caustic chemical handling, etc.

The first Air Knife developed by EXAIR was the Standard Air Knife (formerly known as the EXAIR Knife) and are still quiet and efficient alternatives to drilled pipes, manifolds with open-ended blowing nozzles, and blower-powered air knives. They use a Coanda profile (more on that in a minute) which causes the airflow to turn 90° from where it exits the linear nozzle formed by the shim between the cap & body. This primary air stream entrains surrounding air from the environment, resulting in a total developed airflow that’s 30 time greater than the compressed air consumption of the Air Knife. This entrainment creates a low velocity boundary layer, which reduces the sound level, but there still is some wind shear produced along the Coanda profile.

Because of the end ports in the relatively small profile of the body, there’s 1/2″ on each end where there’s no flow. Since we identify them by the length of the air curtain they generate, Standard Air Knives are physically 1″ longer than their published length (a Model 2012 12″ Aluminum Standard Air Knife has an overall length of 13″, a Model 2018SS 18″ 303SS Standard Air Knife is actually 19″ long, etc.) Full Flow Air Knives use a Coanda profile as well, but they have rear ports, so there’s full flow (as advertised) from end to end. Here’s more on how the Standard and Full Flow Air Knives work:

Compressed air flows through the inlet (1) to the Full Flow (left) or Standard (right) Air Knife, into the internal plenum. It then discharges through a thin gap (2), adhering to the Coanda profile (3) which directs it down the face of the Air Knife. The precision engineered & finished surfaces optimize entrainment of air (4) from the surrounding environment.

The latest, and greatest generation of engineered Air Knife in EXAIR’s arsenal is the Super Air Knife. As detailed above, they offer the most choices in length & materials. They’re also the most efficient, and quietest. Because the airflow exits straight from the linear nozzle formed by the shim gap between the body & cap, with no wind shear, the low velocity boundary layer produced by the entrainment of surrounding air means the sound level (with an 80psig inlet pressure) is a remarkably low 69dBA at a distance of three feet. Any style (Standard, Full Flow, or Super) Air Knife will perform just fine in just about any application that requires a curtain of airflow. If noise level, and/or operating cost, are on your mind, though, the Super Air Knife is certainly worth considering. With just a few details about the application, we can calculate the difference in operating cost for all three models of a given length, and provide you with the ROI (return on investment) for the Super Air Knife. If you’d like to find out more, give me a call.

Russ Bowman, CCASS

Application Engineer
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