Precision screen printing with sub-micron uniformity of metallization materials on green sheet ceramic

A method of forming a puck of a workpiece carrier with electrical traces comprising:

• screen printing a paste that contains metal on a first ceramic green sheet in a pattern of electrical traces, further comprising applying a squeegee of a screen printer to the first ceramic green sheet in a squeegeeing direction while the first ceramic green sheet is on a printer bed of the screen printer;
• mapping the printer bed at multiple locations along the squeegeeing direction;
• applying a statistical spline curve to the printer bed mapping for a left and a right side of the squeegee;
• identifying non-uniformities in the printer bed mapping;
• using the spline curve to actively drive squeegee gaps in the printing direction with smoothed conformal squeegee pressure;
• screen printing the paste on additional ceramic green sheets using the actively driven squeegee gaps;
• forming the first ceramic green sheet and the additional ceramic green sheets into carrier pucks;
• measuring a resistance of the carrier pucks;
• and
• modifying a printer controller of the screen printer to compensate for mapped non-uniformities in the printer bed by adjusting the squeegee gap based on the measured resistance;
• and
• using the modified printer controller of the screen printer, screen printing a paste that contains metal on a second ceramic green sheet in the pattern of electrical traces;
• and
• processing the printed second ceramic green sheet to form the puck of the workpiece carrier.