Electronics Design Workshop

Chapter 2 Electronic Circuit prototyping

Satya P. Singh
Electronics Design Workshop

2.1 Circuit prototyping using breadboard

A breadboard is a type of prototyping

board that allows electronic components
to be connected together in a temporary,
non-permanent way. It is commonly used
for testing and experimenting with circuit
designs before committing to a
permanent soldered circuit. Breadboards have a grid of holes, each of which
corresponds to a connection point for a component lead. The leads are inserted into
the holes and the component is held in place by the friction of the hole. This allows for
easy experimentation and modification of the circuit without the need for soldering.
Breadboards are particularly useful for hobbyist and educational projects, as they allow
for quick and easy experimentation with different circuit designs.

Figure from https://pixabay.com/

2.2 Circuit prototyping using Zero PCB

Zero PCB, also known as "direct PCB," is a method of

creating printed circuit boards (PCBs) without the need
for a physical prototype or breadboard. It is a cost-
effective and efficient way of prototyping a circuit, as it
allows for the creation of a functional circuit board
directly from a computer-aided design (CAD) file.
The process of creating a Zero PCB involves designing
the circuit in a CAD program, such as Eagle or KiCad, and
then exporting the design as a Gerber file. The Gerber file
contains all the necessary information for the PCB manufacturer to create the board,
including the layout of the copper traces, the drilling locations for the component
holes, and the outline of the PCB.
Zero PCB is a popular method for producing small to medium production runs and is
commonly used in industry and by engineers. It allows for faster and more accurate
prototyping, as the design can be tested and refined before the manufacturing
process.

Satya P. Singh
Electronics Design Workshop

2.3 Circuit prototyping using ‘Manhattan’ style:

Manhattan-style circuit prototyping is a technique

for building electronic circuits using stripboard or
veroboard, which are types of pre-cut, pre-drilled
PCBs. The method gets its name from the way the
circuit is constructed, with components and wires
arranged in a grid-like pattern, similar to the streets
of Manhattan.
The process of building a Manhattan-style circuit
involves cutting the stripboard or veroboard to the
appropriate size and then using a soldering iron to
make connections between the components and
the PCB. The components and wires are arranged
in a grid-like pattern, with the leads of the components inserted into the holes on the
PCB and soldered in place. The wires are then used to make connections between the
different components on the board.
Manhattan-style circuit prototyping is a simple and effective way to build electronic
circuits, as it allows for easy experimentation and modification of the circuit. It is often
used by hobbyists and students as it is relatively inexpensive and easy to use.
One of the advantages of Manhattan-style circuit prototyping is that it requires
minimal equipment, making it an accessible method for many people to learn and
experiment with electronics. Additionally, it allows for a more robust prototype
compared to breadboard due to the soldered joints.

2.4 Circuit prototyping using custom PCB

Circuit prototyping using custom PCB (printed circuit board) involves designing a
circuit and creating a custom PCB that is tailored to the specific requirements of the
circuit. This method is used when a more permanent and robust solution is needed,
and when the circuit has been tested and refined through previous prototyping
methods such as breadboarding or Manhattan-style circuit prototyping.
The process of creating a custom PCB typically involves the following steps:
1. Designing the circuit using a computer-aided design (CAD) program, such as
Eagle or KiCad.
2. Exporting the design as a Gerber file, which contains all the necessary
information for the PCB manufacturer to create the board.
3. Sending the Gerber file to a PCB manufacturer, who will create the PCB using a
process such as photolithography or etching.
4. Once the PCB is received, the components are soldered in place.

Satya P. Singh
Electronics Design Workshop

Custom PCBs are commonly used in industry, and are often used for small to medium
production runs. They provide a more robust and permanent solution compared to
breadboarding or Manhattan-style circuit prototyping, and they also allow for more
precise control over the circuit's layout and design. Additionally, custom PCBs are more
cost-effective in mass-production runs.

2.5 Schematic design and PCB layout using Eagle CAD

Eagle CAD is a popular software used for schematic design and PCB layout. It is a
powerful tool that allows users to design and layout circuits for custom PCBs.
The process of schematic design using Eagle CAD involves creating a diagram of the
circuit using the software's built-in schematic editor. The schematic editor allows users
to place and connect components, such as resistors, capacitors, and ICs, using
predefined symbols. Users can also add custom symbols and parts, as well as annotate
the schematic with labels and notes.
Once the schematic is complete, the PCB layout can be done by using the software's
built-in PCB layout editor. The PCB layout editor allows users to place the components
onto the PCB, route the connections between the components, and make any
necessary adjustments to the layout. The software also includes a set of auto-routing
tools that can be used to quickly route the connections between the components.
Eagle CAD also provides features such as DRC (Design Rule Check) that allows users
to check for errors in the design and the Gerber file export, that allows the design to
be sent to the PCB manufacturer.
Eagle CAD is widely used in the industry and by hobbyists and students, as it is
relatively inexpensive and easy to use, yet it provides powerful capabilities for creating
custom PCBs.

2.6 Gerber creation and 3D visualization for fitting Single, double,

and multi layer PCB

Gerber files are a standard format used in the PCB manufacturing industry to
communicate the design of a circuit board. Gerber files contain all the necessary
information for a PCB manufacturer to create the board, including the layout of the
copper traces, the drilling locations for the component holes, and the outline of the
PCB.
Eagle CAD, as well as other PCB design software, can export the design in Gerber
format, these files can be used to create single, double, or multi-layer PCBs, depending
on the complexity of the circuit.
Single-layer PCBs, also known as "single-sided" PCBs, are the simplest type of PCB
and are used for basic circuits. They have a single layer of conductive material, usually
copper, on one side of the PCB.

Satya P. Singh
Electronics Design Workshop

Double-layer PCBs, also known as "double-sided" PCBs, have a layer of conductive

material on both sides of the PCB. This allows for more complex circuits to be built, as
connections can be made between the two sides of the PCB.
Multi-layer PCBs have multiple layers of conductive material, and can have as many
as 12 or more layers, they are used for the most complex circuits, and they allow for a
high density of connections and components.
Gerber files can also be used to create 3D visualization of the PCB, this is a useful tool
for checking the fit of the components and ensuring that the final product will meet
the design requirements. 3D visualization is also useful for checking the routing of the
connections and identifying any potential issues before the PCB is manufactured.
2.7 Single- and double-sided PCB prototype fabrication in the lab
Photo Etching Process:

1. Design the PCB: Create a design of the circuit board using software like EAGLE,
Altium Designer, or KiCAD. Ensure that the design meets your requirements and
is ready for fabrication.

Satya P. Singh
Electronics Design Workshop

2. Clean the PCB: Clean the PCB using a degreaser to remove any dirt or oils that
may interfere with the adhesion of the photoresist. Rinse the board with water and
dry it completely.
3. Print the design onto a transparency: Print the PCB design onto a transparency
using a laser printer. Make sure that the design is the correct size and that it is a
mirror image of the final PCB.
4. Apply the photoresist: Apply the photoresist material ("photosensitive epoxy" or
"photosensitive ink") to the PCB using a spray or dip method.
5. Place the transparency on the photoresist: Place the transparency on the
photoresist with the design facing down. Ensure that the transparency is aligned
with the PCB and secure it in place.
6. Expose the board to UV light: Expose the board to UV light for the recommended
amount of time. The areas of the photoresist that are exposed to the UV light harden
and become resistant to etching, while the unexposed areas remain soft and can be
washed away with a developer solution.
7. Develop the board: Develop the board by immersing it in a developer solution.
The developer solution will dissolve the photoresist in the areas that were not
exposed to UV light. The composition of the developer solution can vary, but a
common recipe is to mix sodium hydroxide (NaOH) or potassium hydroxide (KOH)
with water to create a solution with a pH of around 12. The concentration of the
solution will depend on the type of photoresist being used and the specific
requirements of the PCB fabrication process.
8. Rinse the board: Rinse the board thoroughly with water to remove any remaining
developer solution.
9. Dry the board: Dry the board completely before proceeding with the etching
process.
10. Drill the holes: Use a drill to create holes for the components on the board.

1. Silk-screen printing: This method involves printing the circuit pattern onto the
PCB using a stencil and a conductive ink. The PCB is then etched to remove the
unwanted copper. This method can be used for both single- and double-sided
PCBs.
2. Isolation routing: This method uses a CNC machine to cut away the unwanted
copper on the PCB, leaving the desired circuit pattern. This method can be used
for both single- and double-sided PCBs.
3. Laser cutting: This method uses a laser to cut away the unwanted copper on
the PCB, leaving the desired circuit pattern. This method can be used for both
single- and double-sided PCBs.

After fabrication, the PCB prototype can be assembled by soldering the components
onto the board. It is important to perform a thorough inspection of the PCB to ensure
that the circuit is functioning as intended and that there are no errors in the layout
before moving forward with mass production or further testing.

Satya P. Singh
Electronics Design Workshop

2.8 Soldering using soldering iron/station

Soldering is the process of joining two metal surfaces together by melting a low-
melting point metal alloy, called solder, between them. Soldering is commonly used in
the electronics industry to assemble and repair PCBs (Printed Circuit Boards).
Soldering can be done using a soldering iron or a soldering station. A soldering iron is
a handheld tool with a heating element and a tip that is heated to a high temperature.
A soldering station is similar to a soldering iron, but it includes a temperature controller
that allows the user to adjust the temperature of the tip.
To begin soldering, the tip of the iron or station is heated to the appropriate
temperature. This temperature will depend on the type of solder and components
being used. The tip is then applied to the area where the solder is needed, and the
solder is applied to the opposite side of the joint. As the solder melts, it will flow into
the joint and form a mechanical and electrical connection between the two metal
surfaces.
It is important to use a soldering iron or station with the correct temperature and tip
size for the task at hand. Additionally, it is important to use the right type of solder
and flux, and to keep the tip clean and well tinned to ensure a good quality joint.
Proper technique is also important to avoid overheating the components, which can
lead to damage or poor electrical performance. After soldering, the joints should be
inspected to ensure that they are properly formed and free of defects.

2.9 Soldering using a temperature controlled reflow oven

A reflow oven is a type of equipment used for soldering PCBs (Printed Circuit Boards)
using surface mount technology (SMT). It uses a controlled temperature profile to heat
up the PCB and the components on it to a specific temperature, melting the solder
paste that is applied on the PCB pads, allowing the components to be soldered in
place.
The process of soldering using a reflow oven is called reflow soldering. It is a more
efficient and automated method of soldering compared to manual soldering using a
soldering iron or station. This process is suitable for medium to high volume
production runs.
The process starts by applying a thin layer of solder paste on the pads of the PCB
where the components will be placed. The components are then placed on the PCB
using a pick and place machine. The PCB is then placed in the reflow oven. The oven
heats the PCB to a specific temperature profile, which is pre-programmed and depends
on the type of components and solder paste being used.
The temperature profile typically includes four stages: preheat, soak, reflow, and
cooling. The preheat stage is used to heat the PCB and components to a lower
temperature to remove any moisture or other contaminants. The soak stage maintains

Satya P. Singh
Electronics Design Workshop

the temperature to allow the components to reach thermal equilibrium. The reflow
stage is when the solder paste is heated to a temperature that causes it to melt and
flow, forming a mechanical and electrical connection between the components and
the PCB. The cooling stage is used to cool the PCB and components down to a safe
temperature.
After the soldering process is complete, the PCB is inspected to ensure that the
components are properly soldered and free of defects.
Reflow soldering is a cost-effective and efficient method of soldering SMT
components, but it requires specialized equipment and expertise to ensure that the
process is done correctly and that the soldering quality is consistent.
2.10 Automated circuit assembly and soldering using pick and place
machines

Automated circuit assembly and soldering using pick and place machines is a process
that involves the use of specialized equipment to assemble and solder electronic
components onto a PCB (Printed Circuit Board).
A pick and place machine is a type of equipment that is used to place and position
electronic components onto a PCB. The machine typically uses a vision system to locate
the position of the components on the PCB and a robotic arm to pick up the
components and place them in the correct position.
The pick and place process starts with the PCB being loaded into the machine. The
machine then uses its vision system to locate the position of the components on the
PCB. The robotic arm then picks up the components, one at a time, from a reel or tray
and places them in the correct position on the PCB.
After the components are placed, the PCB is then sent to a reflow oven to be soldered.
This process is called reflow soldering, it uses a controlled temperature profile to heat
up the PCB and the components on it to a specific temperature, melting the solder
paste that is applied on the PCB pads, allowing the components to be soldered in
place.
Automated circuit assembly and soldering using pick and place machines is a cost-
effective and efficient method of assembling and soldering electronic components
onto a PCB. It is suitable for medium to high volume production runs, it improves the
productivity, accuracy and the consistency of the final product.
However, it requires specialized equipment and expertise to ensure that the process is
done correctly and that the soldering quality is consistent. It also requires a proper
maintenance of the machines to ensure that they are operating correctly, and to
minimize downtime.
Exercise:

Satya P. Singh
Electronics Design Workshop

Circuit prototyping using breadboard:

1. What is a breadboard and how does it work?
2. What are the advantages and disadvantages of using a breadboard for circuit
prototyping?
3. How can you troubleshoot a circuit on a breadboard?
4. Can a breadboard be used for high-frequency or high-current circuits? Why or
why not?
5. What are some best practices for using a breadboard for circuit prototyping?
Circuit prototyping using Zero PCB:
1. What is Zero PCB and how is it used for circuit prototyping?
2. What are the advantages and disadvantages of using Zero PCB for circuit
prototyping?
3. How is Zero PCB different from other circuit prototyping methods such as
breadboarding or custom PCBs?
4. What are some best practices for designing and using Zero PCB for circuit
prototyping?
5. How can you troubleshoot a circuit on Zero PCB?
Circuit prototyping using Manhattan style:
1. What is Manhattan style circuit prototyping and how is it used?
2. What are the advantages and disadvantages of using Manhattan style for circuit
prototyping?
3. How is Manhattan style different from other circuit prototyping methods such
as breadboarding or custom PCBs?
4. What are some best practices for designing and using Manhattan style for
circuit prototyping?
5. How can you troubleshoot a circuit built using Manhattan style?
Circuit prototyping using custom PCB:
1. What is a custom PCB and how is it used for circuit prototyping?
2. What are the advantages and disadvantages of using custom PCBs for circuit
prototyping?
3. What are the steps involved in designing a custom PCB?
4. How can you troubleshoot a circuit built on a custom PCB?
5. What are some best practices for designing and using custom PCBs for circuit
prototyping?

Satya P. Singh
Electronics Design Workshop

Schematic design and PCB layout using Eagle CAD:

1. What is Eagle CAD and what is it used for?
2. What are the steps involved in schematic design using Eagle CAD?
3. What are the steps involved in PCB layout using Eagle CAD?
4. What are some best practices for using Eagle CAD for schematic design and
PCB layout?
5. How can you troubleshoot a design created using Eagle CAD?
Gerber creation and 3D visualization for fitting Single, double, and multi-layer PCB:
1. What are Gerber files and what are they used for?
2. What are the steps involved in creating Gerber files for a PCB design?
3. What is 3D visualization and how is it used for fitting single, double, and multi-
layer PCBs?
4. What are some best practices for creating Gerber files and 3D visualization for
PCB design?
5. How can you troubleshoot issues with Gerber files or 3D visualization?
Single- and double-sided PCB prototype fabrication in the lab:
1. What are the steps involved in single-sided PCB fabrication in the lab?
2. What are the steps involved in double-sided PCB fabrication in the lab?
3. What are the materials and equipment required for PCB fabrication in the lab?
4. What are some best practices for PCB fabrication in the lab?
5. How can you troubleshoot issues with PCB fabrication in the lab?
Soldering using soldering iron/station:
1. What is soldering and how is it used in electronics?
2. What are the types of soldering irons/stations and how do they differ?
3. What are the steps involved in soldering components onto a PCB using a
soldering iron/station?
4. What are some best practices for soldering components onto a PCB?
5. How can you troubleshoot issues with soldering using a soldering iron/station?

Automated circuit assembly and soldering using pick and place machines:
1. What is a pick and place machine, and how does it work?
2. What are the advantages of automated circuit assembly and soldering using
pick and place machines over manual methods?

Satya P. Singh
Electronics Design Workshop

3. What factors should be considered when selecting a pick and place machine for
a specific production run?

Satya P. Singh