At Force Technologies, one of the most overlooked — yet critically important — areas of legacy semiconductor support is chip packaging and assembly. Whether you’re trying to extend the life of an aerospace system, maintain defence electronics, or solve component obsolescence, understanding your options around packaging can make or break your project.
We sat down with key members of our technical and leadership team to answer some of the most frequently asked questions about packaging, assembly, and how Force helps customers navigate the complexities of legacy support.
Q: Why does packaging matter so much in legacy component supply?
Karen Salmon FIIOM FORCE TECHNOLOGIES, CEO: “Packaging is often treated like an afterthought; everyone focuses on the die. But the truth is, if the package becomes obsolete, your entire component becomes unusable. You can’t mount it, you can’t test it, and you certainly can’t rely on it in mission-critical systems.”
Q: What types of chip packaging does Force Technologies support?
Ben Savage MIIOM, Applications Manager “We support virtually every type of package — but we specialise in ceramic packaging, particularly legacy formats. That includes CerDIP, side braze, and leadless chip carriers. Most of our clients are in aerospace and defence, and that’s what their systems were built on decades ago.”
Q: What’s the difference between CerDIP and side braze packages?
Ben: “CerDIP packages are built with a ceramic base, a lead frame, and a lid sealed with glass, so they require high-temperature sealing. Side braze, on the other hand, has a lower-temperature seal and the base, body, and lead frame are manufactured as a single unit. Both have strengths, and we can replicate or re-manufacture either.”
Q: If a package is obsolete, does that mean a project is dead in the water?
Karen: “Not at all. That’s where Force comes in. We specialise in resurrecting obsolete packages — even when the original tooling is long gone.”
Ben: “We’ve had situations where we’ve milled out the inside of a package to fit a larger die or rotated the die to match original pinouts. It’s always about finding the most reliable, cost-effective way to make it work — without forcing the customer to spin a new board.”
Q: What does “closed tooling” mean, and can Force work around it?
Ben: “Closed tooling means the original design is no longer available to manufacture. In many cases, we can tweak the original design slightly, sometimes just by a fraction of a millimetre, and re-qualify the package. It’s 99.99% the same, and the customer often doesn’t need to change anything on their end.”
Q: Do customers need to choose between die and packaged inventory?
Charlotte Hughes AIIOM , Sales Manager: “Unfortunately, they often do, and they usually focus on the die. But packages can and do go obsolete too. Investing in packaged inventory may seem like a secondary concern, but it can save massive re-engineering costs down the line.”
Q: How closely does Force work with customer engineering teams?
Karen: “We often bridge the gap between procurement and engineering. In large organisations, those teams don’t always communicate directly — and that’s where delays and confusion creep in.”
Ben: “Whether it’s a direct replacement or a modified assembly, we aim to match the original form, fit, and function as closely as humanly possible. But the final sign-off is always with the customer. We help them make informed decisions based on technical and commercial realities.”
Q: What happens if the die revision doesn’t match the old package anymore?
Ben: “We’ve seen this plenty of times. Die revisions change, and suddenly they’re no longer compatible with legacy packages. In these cases, we work with the customer to either adapt the package, suggest alternative layouts, or even prototype solutions using breadboards or adapters to validate before committing to full production.”
Q: Can Force support low-volume, high-customisation needs?
Karen: “That’s exactly what we’re built for. If you need 10 units in a legacy package, we can do that. If you need something re-tooled with exact mechanical specs, we can do that too. It’s about keeping your systems running without unnecessary expense or disruption.”
Conclusion: Don’t Let Packaging Be Your Project’s Weak Link
Legacy systems deserve legacy expertise. Whether you’re facing obsolete packages, supply shortages, or qualification concerns, Force Technologies offers a custom, controlled, and collaborative approach to packaging and assembly.
If you’ve been told your part is obsolete or the tooling is closed, talk to us. We may have the answer you’re looking for.
Contact me today to discuss your packaging requirements or request a technical consultation with our engineering team.