If you’re exploring mechanical cross sectioning as part of your failure analysis or quality assurance process, you’re not alone. At Cross Section Lab, we work with engineers, quality managers, and procurement leads every day who have important questions before moving forward.
This post answers the most common customer questions to help you feel confident in choosing the right partner for your cross sectioning needs.
1. What is mechanical cross sectioning, and why is it used?
Mechanical cross sectioning is a destructive technique used to inspect the internal structure of a component. It’s commonly used in failure analysis, quality control, and supplier audits to uncover defects like:
- Solder joint voids
- Delamination in PCBs
- Cracked dies or epoxy
- Thin copper plating in vias
- Cold solder joints
It’s the most direct method to expose and document internal features that can’t be seen with non-destructive tools like X-ray or CSAM.
2. What types of components can be cross sectioned?
We routinely cross section:
- Printed Circuit Boards (PCBs)
- Capacitors & resistors
- Connectors & terminals
- Integrated circuits (ICs) & semiconductors
- Medical and aerospace electronics
- Custom mechanical parts
If the part has a failure mode that may exist internally, cross sectioning is likely the right technique.
3. How long does the cross section process take?
Our standard turnaround is 3–5 business days, but rush service (24–48 hours) is available depending on current workload and sample complexity.
Time estimates may vary based on:
- Sample preparation time
- Number of samples
- Reporting requirements
Need something fast? Contact us directly for availability.
4. What’s included in the cross sectioning report?
Our standard report includes:
High-resolution optical images
Measurement data (e.g., plating thickness, void size)
Observations of physical defects
Process conclusions or hypotheses
Optional SEM imaging or EDX analysis (upon request)
Reports are formatted to be client-ready, suitable for internal QA, customer communication, or regulatory documentation.
5. Is cross sectioning destructive?
Yes, mechanical cross sectioning is a destructive technique. The component will be cut and embedded in epoxy, making it unusable afterward. For this reason, it’s typically performed on:
- Failed components
- Samples from production runs
- Units from accelerated life testing (ALT)
6. How much does mechanical cross sectioning cost?
Pricing depends on:
- The number and type of samples
- Complexity (e.g., multilayer PCBs, fine-pitch ICs)
- Whether expedited service or SEM/EDX is required
Typical pricing for basic samples starts around $200–$500 per sample per hour. Contact us for a detailed quote based on your project.
7. How do you handle confidentiality?
We understand the sensitivity of your components and data. Cross Section Lab offers:
- NDA agreements
- Secure sample handling and storage
- Private, confidential reporting
Your IP, product design, and test results are never shared or used beyond your project.
8. How do I send you parts?
We’ll guide you through it:
- Contact us to discuss your needs
- Complete our submission form (we’ll send it)
- Ship your samples to our lab (pack securely)
We recommend anti-static bags for electronics and labeling parts clearly for best results.
9. Why choose Cross Section Lab?
We combine speed, precision, and failure analysis expertise to help you get to the root cause—fast. Our lab is trusted by OEMs, startups, and contract manufacturers across industries like:
- Aerospace & defense
- Medical devices
- Consumer electronics
- Automotive electronics
- Power & energy
You get clear insights, fast turnaround, and lab-grade documentation that decision-makers can trust.