FermionX, a trusted Electronics Manufacturing Services (EMS) provider with nearly five decades of experience, continues to reinforce its commitment to quality and innovation. Under the leadership of Managing Director Will Patrick, the UK-based company has embraced a strategy centered on operational excellence, customer satisfaction, and strategic technology investment. Serving demanding industries such as aviation, defense, and medical technology, FermionX has earned a strong reputation for precision, dependability, and long-term partnership.
The latest step in this ongoing evolution is the enhancement of FermionX’s surface mount technology (SMT) inspection process. Partnering with Altus Group, the company invested in a next-generation 3D Automated Optical Inspection (AOI) solution from Koh Young Technology, a global leader in True 3D inspection systems. The goal was clear: transition from a legacy 2D AOI platform to a highly intelligent inspection system that could elevate performance, reduce defects, and enable data-driven process control.
“This system ensures we are not only producing the highest-quality PCBAs for our customers, but also harnessing the power of data to enhance our process improvement decisions.” – Will Patrick, Managing Director of FermionX
Identifying the Challenge
As FermionX grew, the limitations of its previous 2D AOI platform became increasingly apparent. Programming required substantial engineering time, false calls created unnecessary rework, and inconsistent performance hampered operator trust. These challenges were particularly acute given the growing complexity of the PCB assemblies FermionX produces and the critical nature of the end-use applications. Customers were demanding faster turnaround times and greater reliability, and the inspection system needed to match those expectations. Will Patrick and his team recognized that to uphold their quality standards and maintain efficiency, a shift toward True 3D inspection with metrology-grade performance was necessary.
The Solution: Koh Young Zenith Alpha HS+ with KSMART
After a detailed evaluation process led by Altus Group, FermionX selected the Zenith Alpha HS+ as the ideal platform to meet its current and future inspection requirements. The Alpha HS+ is a high-speed, high-resolution True 3D AOI system that uses a four-projector Digital Light Processing (DLP) engine to accurately measure components and solder joints, even in complex and densely populated assemblies.
Koh Young’s proprietary AI engine supports adaptive inspection capabilities and enables the system to distinguish between real defects and process variations. This results in far fewer false calls and significantly more actionable inspection data. Key benefits highlighted by FermionX include:
- Full 3D metrology improves inspection accuracy to capture detailed component and joint data
- False Call Reduction boosts operator confidence and accelerates inspection review process
- Faster programming enables rapid new product introduction (NPI) without compromising results
- Foreign Material Inspection detects contaminants threatening mission-critical product integrity
- KSMART enables tighter process controls using aggregates data from the line for real-time insights
KSMART, Koh Young’s process control and data management platform, proved especially valuable. It allowed FermionX to visualize trends, monitor real-time performance, and apply Statistical Process Control (SPC) techniques to identify deviations before they became yield-impacting issues.
“The Koh Young system ensures we are not only producing the highest-quality PCBAs for our customers but also harnessing the power of data to enhance our process improvement decisions,” said Will Patrick. “Its advanced software and SPC functionality have allowed us to address issues proactively and improve product consistency.”
Results that Matter
Since deploying the Zenith Alpha HS+, FermionX has reported measurable improvements across several key areas. Inspection false calls have been reduced by over 40 percent, which has streamlined review time and reduced the load on engineering and production teams. Programming time for new products has also been significantly shortened, allowing FermionX to accelerate customer onboarding and reduce time to market.
Most notably, the ability to access real-time inspection data has led to meaningful yield gains and product quality. By identifying process drift early, FermionX has been able to adjust upstream parameters and prevent recurring defects. This proactive approach to inspection enables a culture of continuous improvement across the manufacturing floor.
“Koh Young is widely recognized as the technical market leader, and their innovative platform gives us both confidence and control,” said Will. “This investment reflects our dedication to delivering best-in-class service and positions us to grow further as a trusted UK EMS provider.”
Strategic Partnership with Altus Group
The success of this project was also driven by the support and technical guidance provided by Altus Group, the regional representative for Koh Young. From initial consultation to machine installation and training, the Altus team worked closely with FermionX to ensure a smooth transition and strong return on investment.
“FermionX came to us with a clear vision,” said Joe Booth, CEO of Altus Group. “They wanted to go beyond defect detection and truly unlock the value of metrology-based inspection and process data. With Koh Young and its Zenith Alpha HS+ with KSMART, they have done exactly that.”
He continued, “What impressed us most was their team’s understanding of how inspection data could drive broader operational gains. This is not just about installing a machine. It is about embedding smarter tools into the manufacturing culture. We are proud to have played a role in helping FermionX elevate their inspection capabilities.”
Looking Ahead
The Zenith Alpha HS+ is now fully integrated into FermionX operations, supporting a wide range of high-reliability assemblies. With a strong foundation in place, FermionX is well positioned to expand its service offering, deepen customer relationships, and remain competitive in a fast-moving electronics market. Through its partnership with Altus and the investment in Koh Young, FermionX demonstrates how progressive EMS providers can harness innovation to drive long-term quality, efficiency, and customer satisfaction.
