![Page 1: Homemade Printed Circuit Boards 6/22/2015 Jonathan Weaver, KM4FIK With special thanks to Paul (WA7ZVY)](https://reader030.vdocument.in/reader030/viewer/2022032523/56649d815503460f94a661af/html5/thumbnails/1.jpg)
Homemade Printed Circuit Boards
6/22/2015Jonathan Weaver, KM4FIK
With special thanks to Paul (WA7ZVY)
![Page 2: Homemade Printed Circuit Boards 6/22/2015 Jonathan Weaver, KM4FIK With special thanks to Paul (WA7ZVY)](https://reader030.vdocument.in/reader030/viewer/2022032523/56649d815503460f94a661af/html5/thumbnails/2.jpg)
Overview• Creating PCB Artwork• Getting the PCB Artwork to copper• Preparation before Etching• Etching• Work after Etching• Supplies and Suppliers
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Creating PCB Artwork: Circuit Design
• Find and use• Magazines, books, and references• Online• Component datasheets
• Find and modify• Use specialized tools (logic tools,
filter tools, etc)• Create from Scratch
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Creating PCB Artwork: Circuit Simulation
• Verify that it “works”• Tool: LTSpice (freeware downloadable at
www.linear.com/ltspice)• Alternative: Pspice Student, OrCAD Lite
(free versions of production software with limitations)
![Page 5: Homemade Printed Circuit Boards 6/22/2015 Jonathan Weaver, KM4FIK With special thanks to Paul (WA7ZVY)](https://reader030.vdocument.in/reader030/viewer/2022032523/56649d815503460f94a661af/html5/thumbnails/5.jpg)
Creating PCB Artwork: Schematic• Easy to read• Incorporates notes• Generates a bill of materials (list of parts)• Generates a net list (how the parts are
connected)• Tools: TinyCAD
(http://sourceforge.net/projects/tinycad/)• Alternative Tools:
• ExpressPCB (easiest to learn)• Eagle (freeware has limitations, but very popular)• KiCAD• GEDA (Linux only)• DesignSpark PCB
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Creating PCB Artwork: PCB Layout• Physical Layout
• 600 dpi printing limits the minimum sizes• 15 to 20 mil (1/1000 inch) trace width where
possible. 5 mil trace width minimum (3 dots)• Similar on spacing• 30 to 40 mil holes on 55 to 60 mil pads• Use copper “fill” areas to minimize etching
• Imports net list (parts and hookups)• Includes an auto router (I usually never
use)• Generates manufacturing files (usually
Gerbers)
![Page 7: Homemade Printed Circuit Boards 6/22/2015 Jonathan Weaver, KM4FIK With special thanks to Paul (WA7ZVY)](https://reader030.vdocument.in/reader030/viewer/2022032523/56649d815503460f94a661af/html5/thumbnails/7.jpg)
Creating PCB Artwork: PCB Layout Cont.d
• Free PCB plus ViewMate Gerber Viewer• Alternatives:
• ExpressPCB (easiest to learn but tied to vendor if you want PCB's manufactured)
• Eagle (freeware has limitations)• KiCAD• GEDA (Linux only)• DesignSpark PCB
• At this point you can send the PCB files to a manufacturer or etch a board yourself
![Page 8: Homemade Printed Circuit Boards 6/22/2015 Jonathan Weaver, KM4FIK With special thanks to Paul (WA7ZVY)](https://reader030.vdocument.in/reader030/viewer/2022032523/56649d815503460f94a661af/html5/thumbnails/8.jpg)
Printing a PCB• Print to verify size, etc.• Print for etching (to PDF using PDF Creator)
• Mirror the top side• Bottom side is already mirrored
• Keep the PDF file for easy printing later on• Print using LASER printer on magazine paper
• Alternative papers include • Epson Glossy Ink Jet Photo Paper P/N S041141• Pulsar Toner Transfer System (http://pulsarprofx.com).
Digikey P/N 182-1003-ND and P/N 182-1021-ND.• Line up top and bottom using light under glass
table or light table• Tape two sides down
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Getting the PCB Artwork to Copper
• Clean the copper clad board with a scotchbrite pad
• Insert the board in the print out “pocket”• Iron on high. Cover entire board with iron.
About a minute. Apply good pressure (I usually iron on a counter top).
• Let board “sandwich” cool (sets the ink to the copper).
• Soak the “sandwich” in a sink of cool water• Gently remove paper. Use toothbrush or
sponge to remove small bits of paper stuck to the ink.
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Board Prep before Etching• Inspect!!!!• Use an Exacto knife to cut any "shorted" traces
or pins apart.• Use a fine point sharpie marker to draw in
traces that may have been lifted with the paper removal.
• If it is unrepairable, clean off failed transfer with Acetone, and start over.
• Cut out the board with a Dremel tool (SAFETY GLASSES). Use care not to scratch the design.
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Etching• Bath of hot water• Float bath of etchant (Ferrious Chloride)• SAFETY TOOLS: Latex gloves, safety
glasses, apron or disposable clothes (etchant stains)
• Submerge PCBs. Agitate Etchant. Flip PCBs.
• Repeat until all exposed copper is removed.
• Submerge PCBs in cold water to remove etchant and stop chemical reaction
• Dry PCBs.
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After Etching• CLEAN UP – I store used etchant and reuse.
Etchant can be neutralized with wash powder, dilluted, and disposed down the drain.
• Clean ink off the PCB using acetone (nail polish remover) and scotchbrite pad.
• Drill holes with drill press (etched holes in pads help line up the bit)
• Solder vias through holes (use bare bus wire)• Solder components and jumpers (soldering
would be a whole other presentation)
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Suppliers• Parts
• Digikey (www.digikey.com)• Jameco (www.jameco.com)• Mouser (www.mouser.com)• Others (Radioshack, Element 44, Allied, etc)
• Copper Clad boards and drill bits• Far Circuits (www.farcircuits.net) operated by
KF9GX• He will also etch your boards for you• He accepts ExpressPCB files