PCB Design

Rex Joseph
Department of Electrical and Electronics
Engineering
Pad dimensions - footprint
Soldering (temperature – time)
KiCad
KiCad is a free software suite for electronic design
automation (EDA).

It facilitates the design of schematics for electronic

circuits and their conversion to PCB designs.

KiCad features an integrated environment for schematic

capture and PCB layout design.

Tools exist within the package to create a bill of materials,

artwork, Gerber files, and 3D views of the PCB and its
components.
KiCad
KiCad uses an integrated environment for all of the stages of
the design process: Schematic capture, PCB layout, Gerber
file generation/visualization, and library editing.

A cross-platform program, written in C++ with wxWidgets to

run on FreeBSD, Linux, Microsoft Windows and Mac OS X.

Many component libraries are available, and users can add

custom components on a per-project basis or installed for use
in any project.

There are also tools to help with importing components from

other EDA applications, for instance EAGLE
KiCad
The KiCad suite has five main parts:

•KiCad – the project manager.

•Eeschema – the schematic capture editor.

•Pcbnew – the PCB layout program. It also has a 3D view.

•GerbView – the Gerber viewer.

•Bitmap2Component – tool to convert images to footprints

for PCB artwork.

• Simulation - Netlist
KiCad
Eeschema
Eeschema has features including hierarchical schematic sheets,
custom symbol creation, and an ERC (electrical rules check).

Schematic symbols in Eeschema are very loosely coupled to

footprints in Pcbnew to encourage reuse of footprints and
symbols

(e.g. a single 0805 footprint can be used for capacitors,

resistors, inductors, etc.).
KiCad
Pcbnew

Internally Pcbnew supports up to 32 copper layers and 32

technical layers.

Dimensions are stored with nanometer precision in signed 32-

bit integers making the theoretical maximal PCB dimension
231 nm, or approximately 2.14 meters.

KiCad has a built-in autorouter for basic, single connections.

FreeRouting[10] can be used to externally autoroute boards.
Toporouter, has been adapted for use with KiCad as well.

A DRC (design rules check) is available to check for common

logical errors
EDA Tools
EDA Tools
EDA Workflow
The basic workflow in KiCad is:
1. Create a project.
2. Create a schematic with 'eeschema'.
3. Annotate **
4. Assign footprints to symbols and generate
the netlist. (Automated in V7.0)
5. ERC
6. Create a board with 'pcbnew', importing
the netlist from 'eeschema'.
7. Test the board using the 'Design Rule
Check'.
8. Generate production files. (Gerber files)
KiCAD – Design flow example
Second order filter – Sallen Key
• Single operational amplifier – all footprints in library
• Design variations – based on SMD/Through hole/combination
Component – Packages and Footprints
Packages!
Component – Packages and Footprints
Packages!

Good idea to start with the key component

Component – Packages and Footprints
Packages - footprints
Component – Packages and Footprints
Packages - footprints
Component – Packages and Footprints
Packages - footprints
Component – Packages and Footprints
Component – Packages and Footprints
Packages!

Footprints of passives – wider variety!!

Component – Packages and Footprints
Component – Packages and Footprints
 Component – Packages and Footprints
A resistor's Temperature Coefficient of Resistance (TCR) tells
how much its value changes as its temperature changes.

It is usually expressed in ppm/°C (parts per million per

degree Centigrade) units.
Component – Packages and Footprints
 Component – Packages and Footprints
E 12 Series
 PCB Fabrication
Film Master Preparation, Image Transfer, Photo Printing,
Screen Printing – Chemical Process

Etching the board

• Apply photo-resist to copper foil.
• Expose the photo-resist.
• Develop the pc board and apply dye.
• Prepare etchant solution and etch a pc board.
• Use a carbide-tip drill bit to drill the required
holes in an etched pc board.
• Strip and completely clean an etched board.
 PCB Fabrication
The surface of the foil must first be treated so that selected areas
of the copper can be protected from the etching solution, which
will remove all the copper except the conductor pattern.

The copper may be treated by several methods to accomplish

selective foil pattern protection.

The method to be considered here is photosensitizing.

In this process, the foil is treated with a photo-sensitive resist,
exposed through a 1: 1 negative of the conducting pattern, and
developed.

The result will be a 1: 1 positive conductor pattern produced

onto the surface of the foil, which is etchant resistant
 PCB Fabrication
Film Master

For developing the conductor pattern onto the foil side of

the copper clad pc board, a negative of the original
conductor pattern artwork master is required.

This negative becomes one of the basic elements used to

process either one board for prototype work or hundreds of
boards for mass-production requirements.
PCB Fabrication

This image needs to be transferred to the board before etching.

Etch resist to be present on white areas
Printed side to contact copper surface (Why??) (Top? Bottom ?)
 PCB Fabrication
Board Preparation

The process begins by cutting the necessary-size copper-

clad board from sheet stock.

The work must then be thoroughly cleaned before the

photo-resist is applied.

This cleaning is essential in order to remove all

contaminants, such as grease or copper- oxide film, which
readily forms on exposed copper.

Unless these contaminants are removed, they will adversely

effect the adhesion of the resist with the cop per surface.
 PCB Fabrication
Board Preparation

The application of liquid photo-resist is done by spraying,

dipping, roller coating, low speed whirling, or flow coating.

The first four methods are common to industrial

applications and result in a consistently uniform layer of
resist

Photo resist film is coated on the board using rollers under

heat and pressure - Lamination
PCB Fabrication – Photo-resist Lamination
PCB Fabrication
Exposure of Photo-resist
PCB Fabrication
Exposure of Photo-resist
PCB Fabrication
Exposure of Photo-resist
PCB Fabrication
PCB Fabrication
PCB Fabrication
PCB Fabrication
PCB - Soldering
After Fabrication of PCB
The basics of soldering are the same whether you’re
connecting wires to a speaker or SMT components to a PCB;
you’ll need solder, flux, and heat.

When manufacturing production volumes not going to use

some solder wire and an iron; instead, use solder reflow or
wave soldering depending on the types of components in
your design.

Understanding these processes and principles behind

soldering will help you design to avoid the various defects
that can be difficult to trace and kill a design when it’s time
for production.
PCB Soldering
RoHS is a product level compliance based on the European
Union's Directive 2002/95/EC,

The Restriction of the Use of certain Hazardous Substances

in Electrical and Electronic Equipment (RoHS).

Products compliant with this directive do not exceed the

allowable amounts of the following restricted materials:
lead, mercury, cadmium, hexavalent chromium,
polybrominated biphenyls (PBB) and polybrominated
diphenyl ethers (PBDE), with some limited exemptions.
KiCAD – Design flow example
Second order filter – Sallen Key
• Single operational amplifier – 8 pin TO99
• Capacitors – Ceramic disc, 200 mils spacing, R – 15 cm pitch axial
THANK YOU
Rex Joseph
Department of Electrical
and Electronics Engineering

rexjoseph@pes.edu

+91 80 6666 3333 Extn 515