tutorials given at ComSoc sponsored conferences. (read more)

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GDA Technologies, Inc.
PCB Design Services
GDA has adopted the electronic industry's best practices in PCB design, artwork, and manufacturing, which has lead to a highquality, highvalue customer experience, making their customers best in class in manufacturing circles. (read more)

PCB Etching Equipment — Chemical Etchers
Printed Circuit Board
In 1957, Chemcut developed conveyorized, doublesided spray etching, a technique that made the chemical etching process practical for volume, as well as prototype production. Today, we are the world's largest developer and supplier of PCB etching equipment for advanced electronic interconnect fabrication, with more than 15,000 units in operation.

Chemcut systems integrate process equipment and process controls to fabricate high performance products, in high production volumes, with high yields. Our PCB etching and PCB milling systems are in production seven days a week, yielding over 99% quality printed circuit boards, and we remain uniquely skilled at providing solutions that meet or exceed the electronics industry's accelerating technology and productivity requirements:

Fine Line Etching – Process materials ranging from 2 mil core innterlayers to 250 mil multilayers, and from flexible reeltoreel Kapton to rigid FR4.
Chemcut PCB cutsomers are producing 2 mil trace x 2 mil space circuits at production volumes.
Thin Material Transport – For processing interlayer materials. Chemcut offers a unique comination of conveyor wheels. Today's ultrathin materials are transported without compromising the fluid delivery performance of the processing systems. How to make PCBs at home
in 1 hour & W I T H O U T special materials
If you take your electronics hobby seriously, I guess you already feel the need for a simple and fast technique for making your own printedcircuit boards (PCB). Here I’m going to show how to make simple singlesided PCBs in a snap, using widely available materials. This technique works reliably for thin tracks down to 10 mils, and is suitable for most surfacemount parts. Manufacturer of Printed Circuit Boards (PCB)
Prototype through Production
How to Build PCB?
What it takes to build a Printed Circuit Board?

Printed Circuit Board
PCB Design
PCB Manufacturing (PCB Fabrication)
Physical composition
Substrates
Manufacturing Technique(s)
Patterning/Imaging
Lamination
Drilling
Solder plating and solder resist
Silk screen
Populating
Test and validation
Protection and packaging

Printed Circuit Board
Top
In electronics, printed circuit boards, or PCBs, are used to mechanically support and electrically connect electronic components using conductive pathways, or traces, etched from copper sheets laminated onto a nonconductive substrate. Alternative names are printed wiring board or PWB or etched wiring board.

PCBs are rugged, inexpensive, and can be highly reliable. They require much more layout effort and higher initial cost than either wirewrapped or pointtopoint constructed circuits, but are much cheaper, faster, and consistent in high volume production.

The Two Major Stages for Building a PCB are
PCB Design
PCB Manufacturing ( PCB Fabrication )




PCB Design
Top
Usually an electronics or electrical engineer designs the circuit, and a layout specialist designs the PCB. The designer must obey numerous PCB layout guidelines to design a PCB that functions correctly, yet is inexpensive to manufacture.

The Circuit Design
The Circuit Diagram, also called the Schematic or Logic Diagram, maps out the electronics and connections in the most readily readable form. The designer needs to do background work while producing the Circuit diagram, researching specifications of components, interaction between components (especially timing and loading) physical packages, and arrangement of connector pinouts. The circuit will often start on paper and finish in Computer Aided Design (CAD) format. The finished circuit diagram, supported by notes if required, is the main reference document for the design.

Electronic Design Automation (EDA)
Top
PCB designers often use electronic design automation to produce a layout. The EDA program stores design information, facilitates editing the design, and can also automate repetitive design tasks. C board fabrication using mechanical etching methods is not new. Several companies make equipment using engraving and routing tools to fabricate prototypequality boards. There are a lot of companies out there that many people are not aware of. Check out this site for information on the various machines available, as well as other information related to tooling, materials, methodology, and examples of mechanicallyetched boards.Product Categories for pcb fabrication tutorial
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2 Layer Prototype
PCB Express Inc.

Surface Mount and Through Hole PCB Assembly
Altronics Manufacturing, Inc.

Exotic Material Board
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Engineering Web: pcb fabrication tutorial 1 10 of 20,788
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Product Announcements for pcb fabrication tutorial

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Ryan Screen Printing, Inc.
Asian PCB Fabrication Services
RSP works with the customer on design, prototyping and production. Have your PCB made in Asia and loaded in America. Our world class global network is ready to meet almost any requirements;

RoHS – LeadFree Manufacturing

SPC and Process Control Systems

Certifications: ISO 9001, ISO 14001, TS... (read more)
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SanminaSCI
PCB Fabrication Services
An experienced PCB fabrication resource is a key building block for your electronics products. With SanminaSCI you get a single EMS provider dedicated to providing better manufacturability and collaboration. (read more)

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OakMitsui, Inc.
Polymer Substrate Capacitor Plane for PCB Design
Free up PCB real estate and reduce overall impedance of the power distribution system with FARADFLEX?, Oak Mitsui's revolutionary ultra thin polymer film substrate capacitor plane for PCB fabrication. OakMitsui's licensed Buried Capacitance? technology eliminates the need for some discrete capacitors. (read more)

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STACI
PCB Solutions
For more than 10 years, STACI has been an expert in the production of Printed Circuit Boards (PCB), also called Printed Wired Boards (PWB). From standard technology to the complex, highdensity circuits that incorporate the latest manufacturing and product technology, STACI can meet all of its customers PCB needs, including prototype design, quick turn and production volumes. (read more)

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OakMitsui, Inc.
Copper Foil Leading technology in PCB Market
OakMitsui is recognized as the technological leader in the manufacture of highquality electrodeposited Copper Foils for the printed circuit board industry. As the only U.S. manufacturer (but with the strength of international scope), OakMitsui produces both conventional cladding and application specific Copper Foils required by technology's leading edge companies. (read more)

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Altronics Manufacturing, Inc.
Surface Mount and Through Hole PCB Assembly
Flexible, High tech PCB Assembly in New England! High mix, and high technology capable. They have a fully automatic Surface Mount process as well as complete Through Hole assembly capability. (read more)

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STACI
Rigid and Flex PCB's
STACI offers manufacturers the Total PCB Solution. From standard technology to the complex, highdensity circuits that incorporate the latest manufacturing and product technology, STACI can meet all of your Printed Circuit Board needs. This includes prototype, quick turn, and production volumes. (read more)

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STACI
Aluminum Clad PCB
From standard technology to the complex, highdensity circuits that incorporate the latest manufacturing and product technology, STACI can meet all your Printed Circuit Board needs. This includes prototype, quick turn, and production volumes. (read more)

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IEEE Communications Society
Online Tutorials
IEEE Communications Society's Enhanced Conference Tutorial Program presents a collection of recent
The first stage is converting the circuit schematic into a net list. The net list is conceptually a list of component pins and the circuit nodes, or nets that each pin connects to. Often the schematic capture EDA program, operated by a circuit design engineer, is responsible for netlist generation, and the netlist is imported into the PCB layout program.

The next step is to decide the position of each device. The easy way to do this is to specify a grid of lettered rows and numbered columns where the devices should go. The computer then assigns pin 1 of each device in the bill of materials to a grid location. Typically, the operator may assist the automated placement routine by specifying rooms, or specific regions of the board, where certain groups of components should be placed. For example, the parts associated with a power supply subcircuit might be assigned to a region near the power input connector. In other cases devices may be manually placed, either to optimize the electrical performance of the circuit, or to place components such as knobs, switches, and connectors as required by the mechanical design of the system.

The computer then explodes the device list into a complete pin list for the board by using templates from a library of footprints associated with each type of device. Each footprint is a map of a device's pins, usually with a recommended pad and drill hole layout for each device. The library allows the footprint to be drawn only once, and then shared by all devices of that type.
In some systems, highcurrent pads are identified in the device library, and the associated nets are flagged for attention by the PCB designer. High current runs require wider traces, and the designer or circuit design engineer usually decides the width.

The computer program then merges the netlist (sorted by pin name) with the pin list (sorted by pin name), transferring the physical coordinates of the pin list to the netlist. The netlist is then resorted, by net name.

Some systems can optimize the design by swapping the positions of parts and logic gates to reduce the length of copper runs. Some systems also automatically discover power pins in the devices, and generate runs or vias to the nearest power plane or conductor.

The programs then try to route each net in the signalpin list, finding some sequence of connections in the available layers. Often layers are assigned to power and ground, with one layer to vertical, and another to horizontal wires. The power layers shield the circuits from noise.

The routing problem is equivalent to the traveling salesman problem, and is therefore NP complete, and therefore not amenable to a perfect solution. One practical routing algorithm is to pick the pin farthest from the center of the board, then use a greedy algorithm to select the nextnearest pin with the same signal name.

After automated routing, usually there is a list of nets that must be manually routed.

Once routed, the system may have a series of strategy subroutines to reduce the production cost of the PCB. For example, one routine might remove unneeded vias (each via is a drill hole, and costs money to make). Another might round edges of conductor runs, and widen or move runs apart to maintain safe spacing. Another strategy might adjust large copper areas so that they form nets, or large blank areas may get unconnected "checks" of copper. The nets and checks reduce pollution by extending the life of the etching bath, and speed production by eveningout the copper concentration in the etching bath.

Some systems provide design rule checking to validate the design for electrical connectivity and clearance, rules for board manufacture, assembly and test, heat flow and other errors.

The silkscreen, solder mask, and solder paste stencil(s) are often designed as auxiliary layers.

Finally, the copper layers are then converted to Gerber files, a format of numerical control file for a photoplotter. Historically, an additional aperture file was required to link each numerically designated aperture referred to in the Gerber file with an actual shape to be plotted. Newer Gerber files embed the aperture information in the Gerber file itself. The hole locations are encoded in drill files. The drill files may be sorted to minimize drillhead movement time, and bit changes.

PCB Manufacturing (PCB Fabrication)
Top

Physical composition
Most PCBs are composed of between one and sixteen (or even more) conductive layers separated and supported by layers of insulating material (substrates) laminated (glued) together. Layers may be connected together through drilled holes called vias. Either the holes are electroplated or small rivets are inserted. Highdensity PCBs may have blind vias, which are visible only on one surface, or buried vias, which are visible on neither.

Substrates
Lowend consumer grade PCB substrates frequently are made of paper impregnated with phenolic resin, sometimes branded "Pertinax". They carry designations such as XXXP, XXXPC, and FR2. The material is inexpensive, easy to machine by drilling, shearing and cold punching, and causes less tool wear than glass fiber reinforced substrates. The letters "FR" in the designation indicate Flame Resistance.

Highend consumer and industrial circuit board substrates are typically made of a material designated FR4. This consists of a woven fiberglass mat impregnated with a flame resistant epoxy resin. It can be drilled, punched and sheared, but due to its abrasive glass content requires tools made of tungsten carbide for high volume production. Due to the fiberglass reinforcement, it exhibits about five times higher flexural strength and resistance to cracking than paperphenolic types, albeit at higher cost.

PCBs for high power radio frequency (RF) work use plastics with low dielectric constant (permittivity) and dissipation factor, such as Rogers? 4000, Rogers? Duroid, DuPont? Teflon? (types GT and GX), polyimide, polystyrene and crosslinked polystyrene. They typically have poorer mechanical properties, but this is considered an acceptable engineering tradeoff in view of their superior electrical performance.

PCBs designed for use in vacuum or in zero gravity, as in spacecraft, being unable to rely on convection cooling, often have thick copper or aluminum cores to dissipate heat from electrical components.

Not all circuit boards use rigid core materials. Some are designed to be very or slightly flexible, using DuPont's? Kapton? polyimide film, and others. This class of boards, sometimes called flex circuits, or rigidflex circuits, respectively, are difficult to create but have many applications. Sometimes they are flexible to save space (PCBs inside cameras and hearing aids are almost always made of flex circuits so they can be folded up to fit into the limited available space). Sometimes, the flexible part of the circuit board is actually being used as a cable or moving connection to another board or device. One example of the latter application is the cable connected to the carriage in an inkjet printer. Power electronic applications require lowthermal resisivity substrates, with thick copper track to carry high currents. The main technologies are ceramicbased substrates (Direct Bonded Copper) and metalbased substrates (Insulated Metal Substrate).

Manufacturing Techinque(s)
Top

Patterning/Imaging
The vast majority of “printed circuit boards” are made by adhering a layer of copper over the entire substrate, sometimes on both sides, (creating a “blank PCB”) then removing unwanted copper after applying a temporary mask (e.g. by etching in ferric chloride), leaving only the desired copper traces. A few PCBs are made by adding traces to the bare substrate usually by a complex process of multiple electroplating.

There are three common methods used for the production of printed circuit boards:
Silk screen printing uses etchresistant inks to protect the copper foil. Subsequent etching removes the unwanted copper. Alternatively, the ink may be conductive, printed on a blank (nonconductive) board. The latter technique is also used in the manufacture of hybrid circuits.
Photoengraving uses a photomask and chemical etching to remove the copper foil from the substrate. The photomask is usually prepared with a photoplotter from data produced by a technician using computeraided PCB design software. Laserprinted transparencies are sometimes employed for lowresolution photoplots.
PCB Milling uses a 2 or 3 axis mechanical milling system to mill away the copper foil from the substrate. A PCB milling machine (referred to as a 'PCB Prototyper') operates in a similar way to a plotter, receiving commands from the host software that control the position of the milling head in the x, y, and (if relevant) z axis. Data to drive the Prototyper is extracted from files generated in PCB design software and stored in HPGL or Gerber file format.


Lamination
Top
Some PCBs have trace layers inside the PCB and are called multilayer PCBs. These are formed by bonding together (using high pressure in a press) separately etched thin boards.

Drilling
Holes, or vias, through a PCB are typically drilled with tiny drill bits made of solid tungsten carbide. The drilling is performed by automated drilling machines with placement controlled by a drill tape or drill file. These computergenerated files are also called numerically controlled drill (NCD) files or "Excellon files". The drill file describes the location and size of each drilled hole.

When very small vias are required, drilling with mechanical bits is costly because of high rates of wear and breakage. In this case, the vias may be evaporated by lasers. Laserdrilled vias typically have an inferior surface finish inside the hole. These holes are called micro vias.

It is also possible with controlleddepth drilling, laser drilling, or by predrilling the individual sheets of the PCB before lamination, to produce holes that connect only some of the copper layers, rather than passing through the entire board. These holes are called blind vias when they connect an internal copper layer to an outer layer, or buried vias when they connect two or more internal copper layers.

The walls of the holes, for boards with 2 or more layers, are plated with copper to form platedthrough holes that electrically connect the conducting layers of the PCB.

Solder plating and solder resist
Top
The pads and lands to which components will be mounted are typically plated, because the bare copper is not readily solderable. Traditionally, any exposed copper was plated with solder. This solder was traditionally a tinlead alloy, however new solder compounds are now used to achieve compliance with the RoHS directive in the EU, which restricts the use of lead. Edge connectors, made on the sides of some boards, are often gold plated. Gold plating is also sometimes applied on the whole boards.

Areas that should not be soldered to may be covered with a polymer solder resist coating. The solder resist prevents short circuits between nearby component leads.

Silk screen
Line art and text may be printed onto the outer surfaces of a PCB by silk screening. When space permits the silk screen text can indicate component designators, switch setting requirements, test points, and other features helpful in assembling, testing, and servicing the circuit board. In one sided PCBs, silk screen is also known as the 'red print'.

Populating
In throughhole construction, component leads may be inserted in holes and electrically and mechanically fixed to the board with a molten metal solder.In surfacemount construction, the components are simply soldered to pads or lands on the outer surfaces of the PCB. Often throughhole and surfacemount construction must be combined in a single PCB because some required components are available only in surfacemount packages, while others are available only in throughhole packages.

Test and validation
Unpopulated boards may be subjected to a bareboard test where each circuit connection as defined in a netlist is verified as correct on the finished board. For highvolume production, a Bed of nails tester or fixture is used to make contact with copper lands or holes on one or both sides of the board to facilitate testing. A computer will instruct the electrical test unit to send a small amount of current through each contact point on the bedofnails as required, and verify that such current can be seen on the other appropriate contact points. For small or mediumvolume boards, flyingprobe testers use moving test heads to make contact with the copper lands or holes to verify the electrical connectivity of the board under test.

Protection and packaging
Top
PCBs intended for extreme environments often have a conformal coat, which is applied by dipping or spraying after the components have been soldered. The coat prevents corrosion and leakage currents or shorting due to condensation. The earliest conformal coats were wax. Modern conformal coats are usually dips of dilute solutions of silicone rubber, polyurethane, acrylic, or epoxy. Some are engineering plastics sputtered onto the PCB in a vacuum chamber. Massproduction PCBs have small pads for automated test equipment to make temporary connections. Sometimes the pads must be isolated with resistors.
MEC A Milwaukee Electronics Company Multiple Locations Email this company
Manufacturer
http://www.meccompanies.com/
Company Profile: ISO 9001:2000 custom electronics manufacturer for engineering design, product development, prototyping, circuit board/PCB design, assembly, box build, cabling, JIT, KANBAN, SMT, SMD, BGA, FPGA,...
Website Links: Capabilities

2. SenDEC Corporation CEM Group Fairport, NY Email this company
Manufacturer
http://www.sendeccem.com/content/view/43/180/
Company Profile: ISO 9001:2000 certified assembling services for prototype printed circuit boards, rapid prototyping services & printed circuit board inspection, test & rework. Capabilities include SMT (surface mount...
Brand Names: Sendec Corp.
Website Links: Equipment | Certifications

3. NexLogic Technologies, Inc. San Jose, CA Email this company
Manufacturer, Custom Manufacturer, Service Company
http://www.nexlogic.com/PCBFabrication.aspx
Company Profile: An ISO 9001 certified turnkey PCB manufacturer including PCB design, fabrication, assembly & procurement. PCB design includes schematic capture & layout with single sided & multilayer boards. PCB...
4. Vinatronic, Inc. Huntington Beach, CA Email this company
Manufacturer, Custom Manufacturer
http://www.vinatronic.com/
Company Profile: A contract manufacturer specializing in full service throughhole & surface mount circtuit board assembly. Other services include concept to complete box build, fully tested, design, PCB layout,...
Website Links: Capabilities

5. Electronic Interconnect Corp. Elk Grove Village, IL Email this company
Manufacturer
http://www.eiconnect.com
Company Profile: ISO 9001:2000 certified manufacturer of printed circuit boards (PCB). Capabilities include prototype, single sided, double sided, plated through hole & multilayer PCB's. PCB materials include FR4,...
Website Links: Capabilities | Certifications

6. Sierra Proto Express Sunnyvale, CA Email this company
Manufacturer
http://www.protoexpress.com
Company Profile: PC Board
Website Links: Capabilities | Equipment | Certifications

7. Winonics Inc. Brea, CA Email this company
Manufacturer
http://www.winonics.com/
Company Profile: Printed circuit board (PCB) rapid prototyping services with prototype through medium volume production capabilities. Materials worked include FR4, High Tg FR4, Nelco? 40006, Nanya? NP170,...
Website Links: Certifications

8. Proto Service, Inc. Eden Prairie, MN Email this company
Manufacturer, Service Company
http://www.protoserviceinc.com
Company Profile: Printed circuit board (PCB) rapid prototyping services. Capabilities include assembly of boards with over 30,000 contact points, 30 layer PC boards up to 1 in. thick & over 25 in. long & component...

9. SMS Technologies, Inc. San Diego, CA Email this company
Manufacturer, Custom Manufacturer, Service Company
http://www.smstech.com/smsprototyping.htm
Company Profile: ISO 9001:2000, ISO/TS 16949, QS9000, & AS9100 certified printed circuit board (PCB) rapid prototyping services, engineering services (rapid prototyping), & prototype engineering services....
Website Links: Equipment | Certifications

10. Key Electronics, Inc. Jeffersonville, IN Email this company
Manufacturer, Service Company
http://www.keyelectronics.com/?content=manuf
Company Profile: ISO 9001:2000 certified custom manufacturer of electronic assemblies & depot repair services. Electronic manufacturing services include contract manufacturing for printed circuit board assembly,...
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11. Della Systems, Inc. Ronkonkoma, NY Email this company
Manufacturer, Custom Manufacturer, Service Company
http://www.dellasystems.com/services.html
Company Profile: PCB assemblies, ISO 9002 certified. Electronic contract manufacturer of OEM products; printed circuit board designs & assemblies, SMT & throughhole & mixed technologies, inhouse testing,...
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12. MicroConnex Snoqualmie, WA Email this company
Manufacturer, Service Company
http://www.microconnex.com/index.html
Company Profile: Rapid & direct write prototyping services for printed circuit boards (PCB). Services include positive & negative direct writing, etch resist ablation & electrolytic & electroless plating services....
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13. CGI Circuits, Inc. Taunton, MA Email this company
Manufacturer, Custom Manufacturer, Service Company
http://www.cgicircuits.com/index.html
Company Profile: ISO 9001:2000 certified printed circuit board (PCB) rapid prototyping services. Circuit board prototypes worked with include individually routed singlesided, doublesided, multilayer & prototype...
Website Links: Online Catalog | Certifications