How is a PCB Made?

A printed circuit board, or PCB, is a self-contained module of interconnected electronic components found in devices ranging from common beepers, or pagers, and radios to sophisticated radar and computer systems. The circuits are formed by a thin layer of conducting material deposited, or “printed,” on the surface of an insulating board known as the substrate. Individual electronic components are placed on the surface of the substrate and soldered to the interconnecting circuits. Contact fingers along one or more edges of the substrate act as connectors to other PCBs or to external electrical devices such as on-off switches. A printed circuit board may have circuits that perform a single function, such as a signal amplifier, or multiple functions.

There are three major types of printed circuit board construction: single-sided, double-sided, and multi-layered. Single-sided boards have the components on one side of the substrate. When the number of components becomes too much for a single-sided board, a double-sided board may be used. Electrical connections between the circuits on each side are made by drilling holes through the substrate in appropriate locations and plating the inside of the holes with a conducting material. The third type, a multi-layered board, has a substrate made up of layers of printed circuits separated by layers of insulation. The components on the surface connect through plated holes drilled down to the appropriate circuit layer. This greatly simplifies the circuit pattern.

There is no such thing as a standard printed circuit board. Each board has a unique function for a particular product and must be designed to perform that function in the space allotted. Board designers use computer-aided design systems with special software to layout the circuit pattern on the board. The spaces between electrical conducting paths are often 0.04 inches (1.0 mm) or smaller. The location of the holes for component leads or contact points are also laid out, and this information is translated into instructions for a computer numerical controlled drilling machine or for the automatic solder paster used in the manufacturing process.

Once the circuit pattern is laid out, a negative image, or mask, is printed out at exact size on a clear plastic sheet. With a negative image, the areas that are not part of the circuit pattern are shown in black and the circuit pattern is shown as clear

Manufacturing Process

  • Making the substrate
  • Drilling and plating the holes
  • Creating the printed circuit pattern on the substrate
  • Attaching the contact fingers
  • Fusing the tin-lead coating
  • Sealing, stenciling, and cutting the panels

You can pick many different solder mask colors like purple offered by PCBGOGO

The solder used to make electrical connections on a PCB contains lead, which is considered a toxic material. The fumes from the solder are considered a health hazard, and the soldering operations must be carried out in a closed environment. The fumes must be given appropriate extraction and cleaning before being discharged to the atmosphere.

Many electronic products containing PCBs are becoming obsolete within 12-18 months. The potential for these obsolete products entering the wastestream and ending up in landfills has many environmentalists concerned. Recycling efforts for electronic products include refurbishing older products and reselling them to customers that don’t need, or have access to, newer, state-of-the-art electronics. Other electronics are disassembled and the computer parts are salvaged for resale and reuse in other products.

In many countries in Europe, legislation requires manufacturers to buy back their used products and render them safe for the environment before disposal. For manufacturers of electronics, this means they must remove and reclaim the toxic solder from their PCBs. This is an expensive process and has spurred research into the development of non-toxic means of making electrical connections. One promising approach involves the use of water-soluble, electrically conductive molded plastics to replace the wires and solder.

Have you designed your pcb? want to see what it will look like? Check out this Gerber Viewer from PCBGOGO.

Or do you need a stencil made? Use PCBGOGOs stencil making to get one for your PCB

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