The document outlines the process of manufacturing printed circuit boards (PCBs) including design preparation, etching, milling, assembly, and testing. It discusses in-house production versus third-party manufacturing, detailing the necessary steps, tools, and costs involved. Additionally, it emphasizes the importance of testing and quality assurance to ensure the functionality and reliability of the final product.

1. @omega.teched
@omega_teched
Moving to Manufacture
Manufacturing Printed Circuit Boards,
Etching Boards, Milling Boards, Third
Party Manufacturing, Assembly, Testing

2. Manufacturing
Printed Circuit Board
After completing your PCB
design, the next step is
production. If you only need a
few boards, or want to test them
before ordering in bulk, it’s wise
to make a small batch in-house
first. This allows you to catch
any issues early before
committing to larger quantities.

3. Etching Boards
OMega TechEd
• Prepare the Design: Print your PCB design onto a stencil (either using a photo-
resisting method or toner-transfer with a laser printer).
• Transfer the Design:
o For photo-resist boards, expose the stencil to UV light.
o For toner transfer, use a hot iron to transfer the design to the board.
• Etch the Board: Immerse the board in an etching solution (e.g., ferric chloride) to
remove exposed copper, leaving the circuit traces.
• Drill Holes: After cleaning, drill holes for component mounting (manually or with a
CNC mill).
•The result is a custom PCB ready for component assembly.

4. Milling Boards
OMega TechEd
• Export Gerber Files: First, export the copper layers from your PCB design
software as Gerber files. These files describe the layout of the PCB and are the
industry standard.
• Generate G-code: Use software (often provided with the CNC mill or third-
party software like Line Grinder) to convert the Gerber files into G-code,
which tells the CNC mill how to cut the PCB.
• Milling the PCB: The CNC mill cuts around the copper tracks, isolating them
from the rest of the copper. It leaves larger areas of unused copper intact to save
time and effort, giving the finished PCB a different appearance compared to an
etched board.
• The result is a PCB with neatly isolated copper tracks, achieved through
milling rather than etching.

5. Third Party Manufacturing
OMega TechEd
• If you're looking for a more professional finish or want to avoid making the
PCBs yourself, many companies offer PCB manufacturing services.
• Cost Variation: Prices depend on factors like the complexity, size, and number
of layers in your design. It's wise to get quotes from multiple companies to find
the best deal.
• Lead Time:
• Local manufacturers are faster, with lead times typically measured in
days.
• Overseas manufacturers (e.g., in China) may offer cheaper prices but
usually have longer lead times, potentially a few weeks.

6. Continue…
• Gerber Files: To have the boards made, you need to provide the Gerber
files, which contain the detailed layout of the PCB. Be sure to include:
• All copper layers used in your design.
• Solder mask layer (to prevent solder from sticking to unwanted areas).
• Silkscreen layer (for labels, versioning, etc.).
• Drill files (for hole locations).
• By exporting all the necessary layers, you ensure the manufacturer has
everything needed to produce your PCB accurately.
OMega TechEd

7. Assembly
OMega TechEd
Once your PCBs are manufactured, the next step is to solder the components onto the board.
1. Hand Assembly for Small Runs:
• Through-Hole Components: You can manually solder these with a soldering iron.
• Surface-Mount Components (SMT):
• You'll need the solder paste layer from your Gerber files to create a stencil (which can
be laser-cut from Mylar or steel).
• Use the stencil to apply a thin layer of solder paste to the component pads.
• Place the components carefully using tweezers (magnification helps), making sure not
to disturb them.
• Soldering: You can use a hot-air rework station or a reflow oven to melt the solder and
secure the components.

8. Assembly
OMega TechEd
2. Scaling Up with Robots:
• For larger runs, you’ll need a pick-and-place machine that automatically
places components onto the PCB. This process is fast and precise, using a
vacuum nozzle to pick up and place each component.
• The components are supplied in tape and reel format for the machine to use.

9. Assembly
OMega TechEd
3. Contract Manufacturers:
• If you don't have the equipment or time for mass production, you can outsource
the entire process to a contract manufacturer (assembly house). They can:
• Handle PCB design, manufacture, component sourcing, and soldering.
• Use pick-and-place machines and have skilled staff, allowing for more
efficient and cost-effective assembly.
• Benefits: You save money by not investing in expensive equipment, and the
assembly house can often offer better rates due to their expertise and bulk
buying power for components.

10. Assembly
OMega TechEd
4. Component Sourcing for Contract Manufacturing:
• For common components, you might be able to have the assembly house use
their stock to reduce costs, and they might be able to negotiate better prices
based on their supplier relationships.
In short, for small-scale production, hand-soldering works well, but for large
volumes, contract manufacturers or pick-and-place machines are more efficient
and cost-effective.

11. TESTING
OMega TechEd
Automated Optical
Inspection (AOI)
• AOI uses high-resolution
cameras to inspect PCBs for
defects, comparing them to a
reference board.
• If differences exceed a set
limit, it’s flagged for human
review. AOI is mainly used in
automated lines but can also
be used manually.
Functional Testing
Functional testing ensures the
PCB works correctly by
checking soldering and
component faults, but it may
not detect all issues as it
focuses on basic operation.
Test Rig
• To improve testing accuracy
and efficiency, a test rig can
be built to automate the
process using pogo pins for
reliable, repeatable
connections.
• The rig can test different
circuit parts, measure
voltages, and compare them
to expected values, allowing
faster and more thorough
testing of multiple boards.

12. Advantages
OMega TechEd
• Automated testing ensures high consistency and reduces the chance of human
error in verifying the performance of each board.
• It can significantly speed up the process, especially in high-volume production,
by testing multiple boards quickly and accurately.
• once assembled, the boards should undergo both optical inspection and
functional testing to ensure they are free from defects. Using a test rig with
pogo pins and automated measurements allows for more thorough, efficient,
and scalable testing.

13. Thank You!
@omega.teched
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