LESSON 1

PCB FABRICATION
Steps in PCB Fabrication
Transferring Layout onto Copper-Clad
Board
Print the circuit board layout on glossy
paper, such as magazine paper. Use a hot
iron to transfer the toner onto the
copper-clad board by applying pressure.
The toner requires heat and pressure to
move. After heating the paper for a few
minutes, carefully place the board in a
bowl of water.
Etching PCB etching is one of the most
important elements of the PCB
manufacturing process. It involves
removing copper from the surface of
the PCB in order to reveal the desired
circuit pattern. During the PCB
etching process, all copper is removed
except for the circuitry that is
protected by tin plating.
Drilling
During the PCB drilling process, a
number of different hole types are
drilled. These include via holes (such
as thru-holes, buried holes, blind
holes and micro-holes), component
holes and mechanical holes. Due to
the precision required, holes are
usually carved out using a manual or
laser PCB drill.
Cleaning
First, PCB board is soaked into acetone solvent for
ten minutes. Then, it is placed into quartz
container specialized for absolute ethyl alcohol in
which circuit board is soaked. Next, ultrasonic
cleaning is implemented after placing quartz
container into ultrasonic cleaning tank. Then,
deionized water is used to wash for 5 minutes and
absolute ethyl alcohol is used to carry out
dehydration on circuit board. Finally, nitrogen gas
is used to make the surface dry.
Transferring Layout onto Copper-
Clad Board
a. Acceptable Methods
b. Alternative Methods
Acceptable Methods
Silk Screen
Silk screen is a layer of ink on a printed
circuit board (PCB) that provides
information about the board's
components, test points, and other
circuitry. It can also include decorative
elements like company logos and
branding
Acceptable Methods
There are multiple methods for
transferring layout onto copper-clad
board using Silk Screen, including
manual screen printing, liquid photo
imaging (LPI), and direct legend
printing (DLP).
Acceptable Methods
Manual Screen Printing
This is the oldest and most cost-
effective method. It involves using a
stencil to apply epoxy ink to the
laminate, then drying it. This method is
good for large text sizes and is easy to
set up. However, it's the least precise
method.
Acceptable Methods
Liquid Photo Imaging (LPI)
This method involves coating the
laminate with epoxy, then exposing
it to UV light through a photomask.
LPI is more precise than manual
screen printing, but it's also more
expensive and requires more ink.
Acceptable Methods
Direct Legend Printing (DLP)
This method uses an inkjet printer
to transfer ink directly onto the
board. DLP is the fastest method
and offers high accuracy. It can
print text as small as 0.02 inches.
Acceptable Methods
Photo Printing
A precise process used for
manufacturing integrated
circuits and semiconductors,
where the conductor width
is usually a few microns.
Acceptable Methods

These are the different

types of Photo Printing:
Acceptable Methods
Digital Printing
A high-quality printing method that
uses inkjet or laser printers to produce
detailed images on a variety of media,
including paper, fabric, and plastic.
Digital printing is suitable for a wide
range of uses, from small to large scale.
Acceptable Methods
Lenticular Printing
A process that uses a special plastic sheet with
a lens embossed on one side to create multiple
images from a single printed sheet. The images
appear to move or change when viewed from
different angles. Lenticular printing is used in a
variety of applications, including in-store
displays, packaging, and security documents.
Acceptable Methods
Sublimation Printing
A process that uses heat to permanently print
an image onto fabric. The process involves
printing a design onto special paper, then using
heat to turn the ink into a gas that combines
with the fabric. Sublimation printing is used in
a variety of applications, including clothing,
home decor, and promotional products.
Acceptable Methods
Giclee Printing
A process that uses millions of microscopic
ink droplets to reproduce artwork and
photography on high-quality paper or
canvas. Giclee prints are often considered
to be fine art in their own right and are
prized by collectors and artists.
Alternative Methods
Pen and Tape Method
is a technique commonly used in PCB
(Printed Circuit Board) prototyping,
especially for creating a simple,
homemade circuit board. This method
involves using a pen to draw the circuit
layout and tape to help with alignment or
positioning.
 Etching
a. Chemical
b. Electrochemical
c. Laser
d. Plasma
Etching
Chemical
Chemical etching is a machining
process that uses a corrosive
chemical, usually an acid, to dissolve
away unwanted material from a
surface to create a design.
Etching
Electrochemical
Electrochemical etching, also known as
electrolytic etching, is a metalworking
process that uses an electrical current
and chemicals to selectively remove
parts of a metal surface.
Etching
Laser
Laser etching is a process that
uses a laser to create permanent
marks on a variety of materials by
melting the surface and altering
its profile.
Etching
Plasma
Plasma etching is a technique
that uses a plasma of reactive
ions to remove material from a
surface.
Drill Through-Holes
Drill Through-Holes
Drill through-holes are holes drilled into a
material, such as a printed circuit board
(PCB), to create structures that secure
components or connect layers. These holes
are then plated with copper to establish
electrical connections. This process is
called through-hole technology or
through-plating.
Proper Techniques and Tool
Proper Techniques and Tool
1. Equipment - Use high-quality equipment that’s suited for
the type of PCB’s you’re making.
2. Staff - Hire experienced fabricators or train staff to use the
equipment.
3. Inspections - Conduct inspections at each stage of the
process to identify and fix issues.
4. Collaboration - For complex projects, consider working
with an established PCB manufacturer.
5. Etching - Use a chemical solution bath to etch away the
uncovered copper. Avoid over or under etching to ensure a
straight wall.
Proper Techniques and Tool
6. Plating - Use a series of chemical baths to fill drilled holes
with copper. This allows current to pass from the board's
surface to the inner layers.
7. Surface Finish - Use specialized surface finishing, coating, or
painting to make the PCB more durable.
8. Component Placement - Arrange components according to
the design and layout specifications. However, consider
restricting component placement to avoid electrical noise.
9. Lamination - Stack copper-clad cores and prepreg layers,
then heat and press them in a vacuum to bond the layers.
10. Layer Stackup - Route traces over the shortest path to
improve signal integrity.
Proper Disposal of Chemicals
Proper Disposal of Chemicals
Incineration
High-temperature combustion in an incinerator
approved to burn PCBs is a reliable method for
destroying PCBs. Incineration can destroy PCBs
up to 99.9999%. However, the process must be
closely monitored by trained professionals to
prevent accidents and exposure to toxic fumes.
Proper Disposal of Chemicals
Landfilling
PCBs can be disposed of in a chemical
waste landfill approved under § 761.75 of
the Code of Federal Regulations.
Proper Disposal of Chemicals

Hazardous Waste Landfill

PCBs can be disposed of in a hazardous

waste landfill permitted by the EPA or a
state authorized under RCRA.
Proper Disposal of Chemicals

Chemical Dechlorination
PCBs can be disposed of through chemical
dechlorination. It is a process that uses
chemicals to remove chlorine from water.
Proper Disposal of Chemicals

Alternative Disposal Techniques

PCBs can be disposed of through
alternative disposal techniques that
achieve a level of performance equivalent
to an approved incinerator or boiler.
Standard Procedures
Standard Procedures

Drilling
This step is considered critical and
establishes the foundation for the
connectivity between different PCB
layers.
Standard Procedures

Etching
This process removes unwanted copper
from the board to achieve the desired
circuit pattern.
 Standard Procedures

Lamination
This process binds cores, prepreg, and
copper foil together under high heat and
pressure.
Standard Procedures

Solder Mask Application

Solder resist is applied on both sides of

the board.
 Standard Procedures

Electrical Testing
This step verifies that the board matches
design specifications and functions
correctly.
Standard Procedures

Optical Inspection
This step uses an Automatic Optical
Inspection (AOI) machine to visually
inspect the etched panel.
Standard Procedures

Outer Layer Imaging

This step uses a photoresist material
and optical image transfer methods to
expose the photoresist with UV light.
Standard Procedures

Plating
This step creates plated through-holes,
which are copper-coated holes that
allow electricity to be carried from one
side of the circuit board to the other.
PCB Funtionality Test
PCB Functionality Test
A PCB (printed circuit board) functional
test is a final manufacturing step that
verifies a PCB's functionality and
behavior in its intended environment.
It's also known as FCT testing.
Here are some benefits of PCB
functional testing:
PCB Functionality Test

Detects Defects
Functional testing can identify signal
issues, such as distortions, incorrect
currents, and signal timing
discrepancies. It can also detect short
circuits.
 PCB Functionality Test

Improves Production
Functional testing can help identify
weak links in the manufacturing
process, which can lead to improved
productivity and economic efficiency.
PCB Functionality Test

Reduces Costs
Functional testing can prevent the
production of faulty products, which
can significantly reduce production
costs.
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