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PCB PRINTING
Contents
Introduction ................................................................................................................................ 2
Tools/Components Required ..................................................................................................... 2
Precautions ............................................................................................................................... 10
Conclusion and future scope .................................................................................................... 10
References ................................................................................................................................ 11
Introduction
Engineers around the world use general purpose circuit boards for making everyday projects
and small circuits. Although general purpose boards are very easy to use and also extremely
cheap, they can get very cumbersome when the complexity of the circuit increases. The wires
can get tangled, and even a slight jerk can cause the connections to break off.
Troubleshooting on such a complicated circuit is very time consuming, and kills productivity.
As in the figure alongside, general purpose
circuit boards can cause a lot of trouble
when the complexity of the circuit
increases.
To solve this problem, the designer can
make his own PCB at home, following a
simple DIY project.
The PCB printing machinery used in large scale industries cost several thousand dollars. But
we can still print our own PCBs at home as a simple DIY project.
Tools/Components Required
Item
Price
Hand drill
150
Drill bit 1 mm
30
Copper Clad 6x4 Single
36
Soldering iron
100
Solder wire
60
Sand paper
10
Hydrogen Peroxide 100 ml
20
Hydrogen Chloride household 50 ml
30
PCB design print
30
Other household items used will be fabric iron, plastic box, acetone based cleaner
Software used:
Eagle (Easily Applicable Graphics Layout Editor) is a software developed by Cadsoft and
can be installed as a freeware directly from their website www.cadsoftusa.com. The free
version has some limited functionality, but fulfils our purpose pretty well.
Click on the Add button (or type Add), then type in the component name youd like to
place and add it to the schematic. If a component is missing, you may have to
download the library for that component.
3. Connect the Parts
Connect all parts using the net command. Dont use the wire command as it
doesnt add connections on the board.
Some quick notes on the behaviour of the 'net' command
- It is started with a single-click. Don't click-and-drag or double-click to start.
- It can be started anywhere
- After starting, the net will continue being drawn until you single-click on pin or
another net, or double-click anywhere.
- Single-clicking after starting will anchor the net in the current spot
- Right-clicking will change the way that the net will go from point A to point B. I
personally recommend only using the 90-degree-angle forms of this for schematic
layout
Go to File>Switch to board, and when it warns you that the board doesn't
exist, click Yes to create the board from the schematic.
Move all of the parts into a configuration similar to the one shown in the last
picture.
Typically, when you lay out a board, you first place the parts that have set
locations that they need to go, like connectors. Then, group up all parts that
logically make sense together, and move these clusters so that they create the
smallest amount of crossed unrouted lines. From that point, expand those
clusters, moving all of the parts far enough apart that they don't break any
design rules and have a minimum of unrouted traces crossing.
Put the circuit under running water to soften the paper and carefully rub it off to
reveal the toner design.
5. Etching
Mix HCl and H2O2 in a 1:2 ratio in a plastic box. Place the circuit floating in the
solution and keep checking for remaining copper. Once all the copper has
disappeared, the solution will turn dark green. Remove the circuit, wash it and dry it.
6. Revealing the design
10
The toner can be removed using acetone based cleaning solution or by simply
scrubbing it off using sand paper. Acetone gives a neat finish.
7. Drilling Holes
Holes can be drilled before or after cleaning the toner, as felt comfortable. Use the
hand drill fitted with a 1 mm bit. The circuit on a rubber pad, or any soft but sturdy
surface. Place the drill on the hole point and start drilling slowly till the drill passes
through. Remove the drill by rotating it and drill other holes using the similar
procedure.
8. Finalizing
Brush off the dust from the drilling, attach the components and solder them carefully
according to the designed schematic.
Precautions
Make sure that the correct type of paper is used and printed only using Laser Printer.
Inkjet printers cannot be used for this purpose.
Handle the chemicals very carefully. Use latex gloves and wear eye protection to
guard yourself from fumes.
Do not use a lot of pressure during drilling. This may break the drill bit, or crack the
board.
Scrubbing should not be too hard as the copper may come off.
Soldering should be done with high precision and all points should be checked for
continuity with a multimeter.
The schematic should be strictly followed while soldering the components. Use
proper labels for better accuracy.
Do not touch the iron or the copper clad when its hot.
The plastic container should be strong enough to withstand the heat of the reaction.
Food containers work well for the purpose.
This method of making homemade circuits is much more dependable and flexible than the
traditional method using jumper wires. It reduces the clutter and make the circuit look neat
and compact. It also reduces the possibility of error, and if there are any discontinuities, they
can be checked by just looking at the circuit.
More and more people are moving towards PCBs and it should be encouraged for use by
students all around the world.
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www.instructables.com
www.sparkfun.com
www.cadsoftusa.com
www.egr.msu.edu
References