PCB production, prototyping and component placement

PCB prototyping
Since we do a lot of R&D and small-scale production in the house, we established a small facility for PCB prototype and small-scale production runs.

A single PCB can be milled with our milling machine quickly and accurately. It lacks stop lack (see picture) and silk print, but it is fast and cheap. And perfect for testing RF circuits, prototyping and other design work. Single or double-sided boards with 8-mil traces 0603 can be placed with ease. Our prices are very competitive and it makes perfect sense starting at around 50-100 boards (the problem is stencil mask which can come out a bit expensive per board, if there are not that many of them). Lead-free wave soldering and SMD owens are used.
CAD/CAM PCB design/routing
To round it off we also offer CAD/CAM PCB design, although we are only doing it for smaller boards for the time being as there is usually no time due to other project. If you need this service please check with us first

Artwork
The production of a printed circuit board (PCB) begins the design of the board layout on a Computer Aided Drafting (CAD) package. Once complete, a plot is made of the desired layout in which areas of copper on the final board are represented in black ink while areas to be void of copper are represented by white paper. This hardcopy is two times larger than the final board (2:1) to give better resolution on the final product. The plot is photographed with a copy camera which reduces the image to it's final 1:1 size.

A 1:1 negative is made from the photographed plot. The negative is made by using Litho film in the camera. This type of film produces images that are very high contrast: black and white areas only with no grey. When developed, the image on the negative has clear areas where the original plot was black and black areas where the original plot was white.

Exposing The Board
Photosensitized PCB is placed on top of the negative and UV light shines through the negative to expose it. Clear areas on the negative allow the UV light to pass through and expose the board while black areas of the negative prevent those corresponding areas of the PCB from being exposed to the light below.

Developing The Board

The PCB itself is developed in a chemical solution. Areas of the PCB exposed to the UV light (through the negative) are turned into a plastic film. On areas not exposed to light the film is dissolved away to reveal bare copper beneath. This leaves traces of protective film over areas of the copper which will later become the traces on the board. Exposure and development of the board is done under yellow light to protect the sensitive board from being ruined by exposure to undesired light.

Etching The Board

The board itself is etched in a bath of heated Sodium Persulphate solution. Here, exposed copper is dissolved while copper protected by the plastic film is kept intact. The photo on the right shows a board partially etched in which the fibreglass board behind the copper is visible.

Finishing The Process
The plastic film covering the traces is now strippeed away to reveal shiny copper traces. Copper in the areas between the traces has been etched away to the non-conductive fibreglass board.

Exposed copper on the stripped board is now plated with tin to protect it from oxidation.

A view of the completed PCB, ready for drilling and mounting of components. PCB Design

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PCB Fabrication

PCB Assembly

Material Management PCB Design for Assembly (DFA)

Printed Circuit Board Design for Assembly (DFA) is critical to OEMs who outsource PCBs for design and manufacturing. If correctly performed, it shortens the product cycle, minimizes development cost, and ensures a smooth transition into production from prototype stages. Unfortunately, an OEM product engineering team often accelerates design and development cycles and fails to place emphasis on high volume production considerations such as fixtures, casting, or extrusions, for example. In cases like these, PCB prototype engineers intend to quickly get the product on a test bench, to do proof of concept validation rather than emphasizing Design for Assembly (DFA) considerations.

The prudent approach is to first examine the volume production considerations. The main reason is there are different DFA considerations related to prototype PCB assembly versus production PCB assembly. Each requires a different design skill set and equipment

Author(s): V.M. Evzhenko, A.G. Chebotarevsky

Journal: Circuit World

Year: 1994
Volume: 21
Issue: 1
Page: 5 - 7

ISSN: 0305-6120

DOI: 10.1108/eb046281

Publisher: MCB UP Ltd
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Abstract: An analysis is given of the present situation regarding PCB production in six independent states of the former USSR. The distinctive characteristics of the PCB industry under the command-administrative system which existed until 1991 are outlined. Production capacities of PCB manufacturers and production volumes for 1989–1993 are analysed. An important feature of the market is PCB complexity. The fact that the majority of companies are equipped with domestically produced machinery creates drawbacks. The paper concludes with some proposals for action to increase the efficiency and competitiveness of printed circuit board production in the western part of the former USSR. Inkjet PCB Production Project
FY2003-FY2005; FY2004 Project Budget: 410 million yen
Existing printed circuit boards (PCB) have a multi-layer construction in which four to six layers of metallic wiring with a trace width of about 50 屘m are stacked along with electronic components such as resistors, condensers and input/output terminals. To achieve even finer patterning and higher-density integration, the production cost would have to dramatically increase.
As a solution to this problem, a new system for PCB production is being developed using the inkjet technique. This can simplify the processes required and reduce consumption of materials and energy. Such low-cost, energy-saving multi-layer PCB production technology is also suited to flexible manufacturing, and should lead to finer patterning and higher-density integration.
Specifically, we will develop inkjet printing technology that can produce very fine patterns quickly and steadily as well as a complete PCB production system using inkjet printing. LONDON — Electronics manufacturer Exception Group Ltd. has announced a ￡400,000 investment in new manufacturing technology for its printed circuit (pc) board production facility in Tewkesbury, England. The company has recently taken delivery of a Pola & Massa automated planariser, which is used to reduce excess copper and resin from high density interconnect (HDI) and multilayer high aspect ratio products.

Exception has also invested in an ATG A5 flying probe soft touch test platform. The high-speed system uses 8 fine pitch probes for the electrical testing of prototypes and complex HDI adopted technology, with the ability to test pad features down to 50 micron with zero witness marks, a critical factor in micro BGA and flip chip applications, where the wire bond process is next in the supply chain.

In addition to the planariser and soft touch test platform, Exception has recently introduced a metallisation line to provide an enhanced HDI manufacturing capability, similar to that seen in the fabrication of IC substrates. The facility complements Exception’s current SAP (semi additive process) throughout the company’s wet cells, delivering improved fine line resolution and yield beyond 50 microns Polychlorinated Biphenyls (PCBs)
PCBs Related Links

PCBs & Chemistry
PCBs & Environment
PCBs & Human Health

PCBs, or polychlorinated biphenyls, are a group of chemicals consisting of 209 individual compounds. PCBs were widely used as a fire preventive and insulator in the manufacture of transformers capacitors because of their ability to withstand exceptionally high temperatures. Concern over the toxicity and persistence in the environment of PCBs led Congress in 1976 to enact the Toxic Substances Control Act (TSCA) that included, among other things, prohibitions on the manufacture, processing, and distribution in commerce of PCBs.
PCBs have been demonstrated to cause a variety of adverse health effects. PCBs have been shown to cause cancer in animals. PCBs have also been shown to cause a number of serious non-cancer health effects in animals, including effects on the immune system, reproductive system, nervous system, endocrine system and other health effects. Studies in humans provide supportive evidence for potential carcinogenic and non-carcinogenic effects of PCBs.

PCBs build up (bioaccumulate) in the environment, increasing in concentration as you move up the food chain. This is of special concern in areas where fish are exposed to PCB contamination and may be consumed by humans (as in the Hudson River). At the Hudson River PCBs site, the best way humans can reduce their risk of exposure to PCBs is by following the New York State Department of Health advisories for consumption of fish from the river.
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Mentor Graphics Publishes New Technology Book On BGA Routing

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PCB Production - 27 Jun 2008

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DuPont Electronic Technologies Announces Global Price Increase

News, PCB Production - 26 Jun 2008

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PD Circuits Expands China Operations

News, PCB Production - 24 Jun 2008

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Rohm and Haas Announces a Comprehensive Set of Actions to Restore Profitability

News, PCB Production - 18 Jun 2008

Rohm and Haas Company has announced a comprehensive set of actions to restore profitability and ensure the achievement of its Vision 2010 goals by realigning its manufacturing footprint and support se...

Ibiden to Invest RM1 Billion on Second Malaysian PCB Facility

PCB Production - 21 May 2008

Ibiden Co Ltd announced that it plans to set up its second PCB manufacturing facility in Malaysia to complement its existing plant in Beijing, China. In a statement in Kuala Lumpur to The New Straits ... Our products

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Well, you can be safe in the knowledge that at ABL Circuits you will be dealt with in a friendly and highly professional manner and with all your requirements logged onto our sophisticated computer system. You will get exactly what you asked for on time, every time .. So you can plan your production time accurately.

You can benefit from our 18 step PCB production process including inspecting your photography to CNC drilling your printed circuit boards. From etching the copper to photo-image resist.

You will receive your single or plated through printed circuit boards within 5 working days as standard ..

.. and your multi layered circuit boards within some of the best turnaround times within the PCB Industry. You can even choose our 8 hour prototype service if there's a particular project you need urgently.

What is more, your printed circuit board will receive seven different inspections as they progress through the PCB production process. Ensuring that every one of your printed circuit boards reaches you in perfect condition. We aim to be your choice for a UK PCB manufacturer.

You can request our brochure online on our web site. Or, if you prefer simply call us on 01462 894312 and we'll put our brochure in the post for you.

As always, your feedback is very important to the success of this site and our business. Your thoughts and comments would be greatly appreciated.Manufacturing of Original PCB

I will introduce about the making of the Printed Circuit Board(PCB)
which I use when I assemble the electronic circuits from this page.

About the Printed Circuit Board
Implement of the Printed Circuit Board making
Process of the Printed Circuit Board making
Making of the Double sided printed board
Cool-Amp silver plating
CAD software EAGLE

The circuit board when I assemble the electronic circuits is generally using the one which is called "The universal circuit board".
As for the reason, the circuit to make is because it makes only once.
Generally, I don't make many sheet of the printed boards with the same pattern.
Also, when changing the circuit after the operation confirmation of the circuit, the universal circuit board is convenient.

However, when trying to make all electronic circuitses with the universal circuit board, there is a limit.
The case where had better make the Printed Circuit Board is shown below.

The circuit which handles the high frequency

In case of the circuit which handles the high frequency (the MHz order), the length of the wiring, the way of letting through the wiring have an influence on the circuit operation. Because it is, it is necessary to investigate the length of the wiring, the distance with the other circuit.

When doing the high density assembly

In case of the universal circuit board, the hole to mount the part becomes the 0.1-inch interval.
Because it is, in the case which mounts with the part in the interval below it, the Printed Circuit Board must be made.

When the lead line of the part is not the 0.1-inch interval

For example, in case of the transformer for the high frequency, the lead line of the shielding case is not the 0.1-inch interval to the lead line of the coil.
Because it is, when mounting such a coil on the universal circuit board, a hole for the lead line of the shielding case must be made in the circuit board.
Or, it makes turn the 45° and it mounts.Products ? Project Design and Development Services ? PCB Production

PCB Production

Contact us for pricing

QuickFind Code: QF378
Category: Project Design and Development Services
Product Information
Crownhill can handle your PCB layout and schematic capture requirements. With a commitment to high quality and reasonable pricing you receive your completed design on time and within budget. We handle both new designs as well as updating existing boards. Designs may be either a netlist or a hand drawing. All sizes and complexities of designs are welcomed. Multi-layer PCB's, split planes, surface mount (SMT) and through hole are standard. In addition to hand routing of critical signals we use industry standard PCB layout and schematic capture tools to bring your design to reality, in accordance with your specifications. Netlists and existing PCB's created from various tools are supported. You receive check plots, Gerber files (RS274X format), drill file(s), fabrication drawings, assembly drawings and if applicable, schematics and parts list.

To provide a quotation we will require: turnaround, or while you wait ( by proir arrnagement). We can also provide multi layer boards upto 12 layers. On single or double sided boards and some four layer boards, CAM files received before 9am by email and paid for by credit card can be despatched as finished PCBs for delivery overnight to any destination on the UK mainland.

For our fast 24hr or "special" while you wait service the following rules apply:

Minumum Charge
￡30.00 for 10sq cm Single sided no PTH rising to
￡40.00 for 10sq cm Double sided with PTH, larger sizes pro-rata, send design files for a quotation
Circuits supplied can be 1 or 2 layer 0.8 or 1.6 mm Fr4 with Plated Through Holes.
Finished in bare copper tracks and pads on both sides.
Minimum track and gap 0.2 mm
Holes can be PTH or NON PTH, as defined in your gerber files or by your written description.
Only top and bottom copper layer files, excellon CNC drill files, and a profile layer file will be used. All other files will be ignored.
Profiles will be cut with a 2.00 mm or 1.00 mm diameter router as a simple single pass
Profiles must be drawn with a single continuous line, the inside or outside can be used as the cutting line, you must specify which. (default is cutting outside).
Internal cut-outs, circles and slots are permissable, please notify us of these or unusual board profiles (Stars or polygon shapes)
Panelisation and step & repeating is allowed
Please include "readme" files & design notes to aide manufacture
Legends in copper are permissable
Note: For this service

No solder resists
No alterations, editing, or additional instructions regarding the circuits may be made after webeing work on your order
No design rule checking is performed by us
Electrical test is not included
No scoring or tabs, unless discussed with us and agreed in advance, your design notes must be acceptable to us.
No gold or other finishes
Minimum CNC drill size is 0.30mm, maximum CNC drill size is 1.5 mm, larger holes are routed

Data must be received by 9am on a working day and we will ship by close of business the same day or following working day, to be agreed when payment is received.

Please check your files with GC-Prevue before submitting them to us.

The maximum number of circuits available is 2 depending on the size of the circuits, but ask us to quote.

Overnight shipping is ￡10.00 within the UK. Please enquire regarding overseas shipping costs.