How to Create Printed Circuit Boards (With Pictures)

So you have the circuit designed and ready. You did some simulations with the computer and the circuit is working excellent. Only one thing is missing! You need to create a printed circuit board (PCB) so you can see it in action. Whether the circuit is a project for school or university or is the electronic final piece of a professional product for your company, implementing the circuit on a PCB will give it a much more professional appearance, as well as giving you an idea on how! the finished product will look! This article will show you the different methods by which you can create a printed circuit board (PCB) for an electrical or electronic circuit with different methods suitable for small to large circuit systems.

Steps

Step 1. Choose a method to create the PCB

In general, the choice will be based on the availability of the materials required by the method, the level of technical difficulty of the method, or the quality of the PCB you want to obtain. Here is a short summary of the different methods and their main characteristics that will help you decide:

1. Acid Etching Method: This method requires extreme security and the availability of many materials, such as etcher, and is a bit time consuming. The quality of PCB you get varies according to the materials you use, but it is generally a good method for circuits that are simple to intermediate in complexity. Circuits that involve tight wiring and tiny wires usually use another method.
2. UV Etching Method: This method is used for transposition of PCB layout to PCB and requires materials that may not be available everywhere. However, the steps are relatively simple and more complicated and finer circuit designs can be produced.
3. Engraving or Mechanical Routing Method: This method will mechanically remove unnecessary copper from the board or route empty standoffs between wires. It can be expensive if you plan to buy one of these machines and generally requires the availability of a nearby workshop to rent. However, this method is good if you need to create a lot of copies of the circuit and it can also produce thin PCBs.
4. Laser Engraving Method: Usually this is used in large production companies, but can be found in some universities. The concept is similar to that of mechanical engraving, but LASER rays are used to engrave the plate. Such machines are generally difficult to access, but if your local university is one of the lucky ones to have them, you can use their facilities, if they allow you.

   

   Step 2. Create the circuit PCB layout

   Usually this is done by converting the circuit schematic diagram into the PCB layout with the help of PCB layout software. There are many open source software packages for PCB creation and design, here are a few to help you get started:

   • PCB
   • Liquid PCB
   • Shortcut

   

   Step 3. Make sure you have obtained all the materials that the method you choose requires

   Step 4. Draw the circuit layout on the copper-clad plate

   This is applicable only for the first two methods. You will find more details in the section of the method you choose.

   

   Step 5. Etch the plate

   To find out how to engrave the plate, go to the sections where the process is detailed. This process removes all unnecessary copper from the board, leaving only the final circuit wiring.

   

   Step 6. Drill installation points

   The drills used for this are usually custom machines designed specifically for this purpose. However, if you make a few adjustments to a regular hole punch, this will work for you at home.

   

   Step 7. Install and solder the electronics to the board

   Method 1 of 2: Specific Steps of the Acid Etching Method

   

   Step 1. Choose the acid to etch

   Ferric chloride is a common choice to use as an etcher. However, you can use ammonium persulfate crystals or other chemical solutions. No matter what you choose as a chemical etcher, it will always be a hazardous material, so in addition to following the general safety precautions mentioned in this article, you should also read and follow any additional instructions that come with the etcher.

   

   Step 2. Draw the PCB layout

   To etch with acid, you have to draw the circuitry with etchant-resistant material. You can easily find special markers for this kind of purpose if you plan to draw it by hand (not suitable for medium to large sized circuits). However, the most commonly used material is ink from laser printers. The steps to use the laser printers to draw the circuit design are as follows:

   1. Print the PCB layout on glossy paper. You need to make sure the circuit is reversed before doing this (most PCB design programs have this printing option). This only works with a laser printer.
   2. Place the satin side, with the print on it, facing the copper.
   3. Iron the paper with a regular clothes iron. The amount of time it takes will depend on the type of paper and the ink you use.
   4. Soak the plate and paper in hot water for a few minutes (10 minutes maximum).
   5. Remove the paper. If some areas look especially difficult to peel, you can try soaking it a little longer. If all goes well, you will have a copper plate with the PCB pads and signal lines drawn with black toner.

      

      Step 3. Prepare the acid etcher

      Depending on the “acid etcher” you choose, there may be additional instructions. For example, some crystallized acids must be dissolved in hot water, but other etchers are ready to use.

      

      Step 4. Dip the plate in the acid

      

      Step 5. Make sure to stir every 3-5 minutes

      

      Step 6. Remove the plate and wash it after all unnecessary copper has been removed from the plate

      

      Step 7. Remove the insulating material from the drawing that you used

      There are special solvents available for almost all types of drawing insulating material that are used to draw the PCB layout. However, if you don't have access to any of these materials, you can always use sandpaper (a fine one).

      Method 2 of 2: Specific Steps of the Ultraviolet Transposition Method

      Step 1. To apply this method, you will need a PCB with a photosensitive film (positive or negative), a UV insulator, a transparent sheet and distilled water

      You can find the cards ready to use (they are covered with a black nylon sheet) or a photosensitive spray to apply on the copper side of a common blank PCB card. Make sure to also purchase a photographic developer that is compatible with the photosensitive spray or photosensitive coating on the PCB.

      

      Step 2. Using a laser printer, draw the PCB layout on the transparent sheet, in positive or negative mode, according to the photosensitive coating on the card

      

      Step 3. Cover the copper side of the board with the printed transparent sheet

      

      Step 4. Place the plate in the UV isolation chamber or machine

      Step 5. Turn on the UV machine

      This will irradiate the plate with UV rays for the specified amount of time. Most UV insulators are equipped with a programmable timer. Usually 15-20 minutes will be more than enough.

      Step 6. When done, remove the UV insulator plate

      Clean the copper side of the card with the photographic developer and then carefully rinse the developed PCB with distilled water before placing it in the acid bath. The parts destroyed by UV irradiation will be etched with the acid.

      Step 7. The other steps to follow are described in steps 3 to 7 of the acid etching method

      Warnings

      • If you use the acid etching method, you need to take the following precautions:
        • Always store acid in a cool, safe place. Use glass containers.
        • Label the acid and store it in a place that is out of the reach of children.
        • Don't dispose of used acid down the house drain. Instead, store it, and when you have a good amount of used acid, take it to a recycling center or hazardous waste disposal facility.
        • Wear gloves and respirators when working with acid etchers.
        • Be very careful when mixing and stirring the acid. Do not use metal objects and do not place the container on the edge of the disc.
        • When irradiating the PCB with UV, be careful not to have direct eye contact with the part of the chamber or isolator that generates the radiation, or wear UV protective goggles. If you have to check the PCB during the process, it is better to stop the machine before opening it.