AI-driven point cloud framework for predicting solder joint reliability using 3D FEA data

Crack propagation in solder joints remains a major challenge impacting the thermo-mechanical reliability of electronic devices, underscoring the importance of optimizing package and solder pad designs. Traditional Finite Element Analysis (FEA) techniques for predicting solder joint lifespan often rely on manual post-processing to identify high-risk regions for plastic strain accumulation. However, this manual process can fail to detect complex and subtle failure mechanisms and purely based on averaging the creep strain and correlating it to lifetime values collected from experiments using Coffin Manson equation. To address these limitations, this study presents an Artificial Intelligence (AI) framework designed for automated 3D FEA post-processing of surface-mounted devices (SMDs) assembled to Printed Circuit Board (PCB). This framework integrates 3D Convolutional Neural Networks (CNNs) and PointNet architectures to automatically extract complex spatial features from 3D FEA data. These learned features are then linked to experimentally measured solder joint lifetimes through fully connected neural network layers, allowing the model to capture complex and nonlinear failure behaviours. The research specifically targets crack development in solder joints of ceramic-based high-power LED packages used in automotive lighting systems. This dataset included variations in two-pad and three-pad configurations, as well as thin and thick film metallized ceramic substrates. Results from the study demonstrate that the PointNet model outperforms the 3D CNN, achieving a high correlation with experimental data (R² = 99.91%). This AI-driven, automated feature extraction approach significantly improves the accuracy and provide the more reliable models for solder joint lifetime predictions, offering a substantial improvement over traditional method.