Getting a PCB Made

Printed circuit boards, or PCBs for short, are essential to everyday technology. They are the cornerstone of electronics and provide an efficient way to connect internal components without a mess of wires. But how are printed circuit boards made? A lot goes into it, but getting a PCB made is easier than you may think. It just takes the right partner, that can ensure you have the PCB design you want, with a focus on manufacturability and cost-efficiency. We utilize all the best design software, manufacturing, inspection, and test equipment to make sure you get what you want the first time. 

 

What Are PCBs?

Simply put, printed circuit boards are electronic components that utilize conductive elements such as tracks and pads that are etched from laminated copper onto layers of non-conductive substrate layers. Typically, the components are soldered onto the board. Before PCBs were developed, the components within electrical devices would require loose wires to connect components. The wires would often crowd the device making the device larger and inefficient. However, PCBs replace these wires with tiny connections called “traces” across a non-conductive board. Since the boards are much smaller, they allow a large number of components to be connected without cumbersome wires everywhere. Printed circuit boards are found everywhere—computers, phones, clocks, switch boxes—the list goes on and on. 

 

What is PCB Manufacturing?

PCB manufacturing is the process of building these little technological wonders. Whether you only have a concept, a schematic, or a completed PCB design, we can help guide you through the process. Once all the details are defined, our team will begin crafting the board to your specifications. 

 

Steps to Getting a PCB Made

Step 1: Design & Prepare Files

The development of your PCB always begins with the design. If you need help in this area, we are here to help. Once the design is completed, it’s time to get a few essential files ready for the manufacturer. 

• A Gerber File – This file gives the manufacturer all the information they need about solder masks, copper lays, and silkscreens.
• A Drill File – Every drill hole needs to be precise which is why a special file for drill hole placements and sizes is required to build your PCB.
• A Netlist File – Every component needs to be connected in a specific way, so it helps the manufacturer to have a file that offers detailed information on what needs connections.

 

Step 2: Creating a Roadmap 

From here, the manufacturer will take over the process and will begin by creating a roadmap of your PCB. This can be accomplished in a couple of different ways. Some manufacturers use large film printing machines to map out the internal layers while others utilize advanced lasers to transfer images directly to the panels.

 

Step 3: Copper Lamination & Alkaline Bath

Once the layers are printed, they are laminated onto copper panels and eventually coated with photosensitive film. A UV light is then used to solidify the photosensitive film which further defines the copper designs on the board. 

Once finished, the panels are given an alkaline bath to remove excess copper allowing your original design patterns to shine through. Inspection software is then used to compare the panels to the design files provided to ensure everything is on track.

 

Step 4: Foil Layers & Drilling

After the copper panels are examined, a skilled technician will add layers of foil on top along with a special type of fiberglass mixed with glue. These components are then combined with heat and pressure.

Once cooled, the drilling process can begin. The panels are taken to an advanced drilling machine for vias and through-hole components. After this stage is complete, each panel is given a copper bath.

 

Step 5: Copper Lamination & Solder Mask

Next, images for the outer layers of the PCB are created with copper patterns. This is the exact process seen in Step 3 and the layers are then submerged in another copper bath.

With each layer almost fully assembled, the top and bottom panels are given a coating of solder mask. This prevents rusting and also gives the panel a nice green or blue hue.

 

Step 6: Testing & Assembly

Before we assemble your printed circuit board, it’s important to ensure there won’t be any short circuits. This is accomplished by a few electrical tests with a grid tester or flying probe.

 

Step 7: Inspection & Component Installation

Before components are added, a certified technician will look over the boards to see if there are any imperfections, incorrect hole sizes, cosmetic issues, and other flaws.

Once inspected, populating the PCB can begin.

Solder paste is applied and inspected to make sure it is in the right locations, at the right volumes prior to installing components. Next, the components are installed and inspected to make sure they are the correct parts placed in the correct locations. Once everything has been verified, the components are attached to the PCB by reflowing the solder in an oven. This reflow process is strictly monitored and controlled to ensure the best results without the risk of damage to the components or PCB. Once the components have been soldered to the PCB, another inspection is performed to make sure no defects have occurred.

Once populated, your PBC becomes a PCBA (Printed Circuit Board Assembly). 

 

So, that’s PCB assembly in a nutshell. Of course, there’s a lot more that goes into it, and technicians dedicate their entire careers to perfecting this process. Each step requires advanced, custom technology and an experienced eye to ensure a quality product. For all your PCBA manufacturing needs, trust Geospace Technologies to provide custom PCBA solutions created to your exact specifications. Visit us online or contact us directly to get started!