Saturday, April 2, 2011

Making of a PCB (watch in HQ)

After much trial, I finally was able to produce a functional "Printed Circuit Board". Along the way, I learned that "Inkjet" and "Laserjet" are not the same printing process in very microscopic way (toner is the key to transfering the image of circuit pattern from paper to copper). The most challenging aspect of toner transfer is getting all the toner to transfer. Paper selection, time/patience and effort (applying lots of pressure on Iron to "push semi-liquid toner onto copper). Maybe a key process is the "Quenching". I finally took that one step further than I had seen from other YT videos on subject...I laid the board on Ice (freeze the toner quickly). I should have flipped the CB over, so that cooling first occurs on the copper side (not the paper side) to enhance toner-transfer. Furthermore, I took the step of removing the "Oxidation Layer" on Copper board to more extreme level, by wet-sanding the board to a near mirror-finish. Finally, I drilled the holes with a #65 drill bit. I have since bought a #76 drill bit (even smaller), there were some issues with the copper "mushrooming out" at the edges fo the pad. This is not good. I'll add updates (Text) as I learn more during my "Low-rate Production" effort (presently testing "Manufacturability" of unit).

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