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options are manual PCB shears and automated PCB cutting machines.
Selecting the right PCB cutting method requires evaluating key factors like
cut quality, throughput, cost, complexity, and capabilities for the types of
Table of Contents
scissor-like shearing.
PCB shears are a simple, low cost cutting option but require skilled
Using PCB shears for cutting involves the following key steps:
Board Positioning
Clamping
shifting.
Shear Actuation
The operator manually squeezes the shear handle to close the blades
Indexing
The board is manually indexed to the next cut location and aligned.
Cut Repetition
Several factors impact the cut quality and consistency using PCB shears:
Deburring process
Dedicated tools like perforated or scored cut lines aid shear positioning.
But ultimately the operator controls key variables influencing cut quality
Shears are an inexpensive cutting tool option with prices from a few
thousand dollars.
Simple Operation
or programming.
Quick Setup
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sizes.
Small Footprint
Flexibility
variations.
Low Maintenance
replacement.
While useful in some scenarios, PCB shears have some distinct limitations:
Inconsistent Quality
Lower Throughput
Larger Kerf
machining.
Burr Management
Limited Automation
Here are typical production situations where PCB shears may be the
include:
Router-Type Machines
Use a rotary end mill tool spinning at high RPM to cut boards.
Knife Cutters
Laser Cutters
profiles.
Waterjet Cutters
The required cut pattern is defined in software based on board panel sizes,
Board Loading
Panels are automatically loaded onto the machine bed from a conveyor or
Optical Alignment
Cutting
The spinning end mill, knife blade, laser or waterjet traverses the tool
Unloading
Conveyors remove finished cut boards and scrap from the machine.
Verification
Precision
Consistency
Cut Quality
Kerf Width
Productivity
Cut rates from 10 to over 100 boards per hour depending on size
and complexity.
Reliability
Automation
processes.
production volumes.
Labor Savings
Improved Yields
defects.
Higher Throughput
Scalability
adding machines.
Reduced Costs
Lower cost per cut board through labor savings and efficiency gains.
Quick Changeovers
cutting:
Equipment Costs
Programming
cut patterns.
Maintenance
Floorspace
Machines have larger footprint than shears and may require special
facilities.
Operators
Changeover Time
Here are typical high volume production scenarios where automated PCB
Hybrid Approach
This hybrid model allows optimizing the strengths of each technology for
different needs.
recommendations:
For low volume PCB cutting under 5000 units per week, with less
For cutting volumes over 5000 PCBs per week, tighter cut tolerances, and
In facilities with high mix production across both low and high volume
boards, a hybrid approach with both shears and cutting machines allows
Technology Evaluation
cost.
Conclusion
Both PCB shears and automated cutting machines have their place in PCB
A: Perforated or scored lines on the panel help guide the operator during
A: Shears can cut simple rigid-flex boards but automated machines offer
sharpening, and calibration. Replace worn blades for best cut quality.
Related Posts:
https://www.raypcb.com/pcb-shears/