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http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/
License: Attribution Share Alike (by-sa)
This Instructable will show you how to use your inkjet printer to etch your own printed circuit boards, as well as be able to display a printed component footprint on the top
side of the board giving you a professional looking design.
CAUTION:
For this instructable you will be working with chemicals and power tools. Please wear appropriate protective wear. i.e. goggles, latex gloves, etc.
The chemicals used in this instructable will stain clothes and your skin.
DO NOT pour chemicals down your drain. Properly dispose of chemicals according to your local waste management.
Chemicals used in this instructable will eat metal. i.e. your copper plumbing pipes, metal sink, etc.
Why would you want to etch your own printed circuit board from home? For one it can be cheaper than sending your boards out to a fabrication company. The
second reason is if you are planning to send your boards out to have them professionally done, by printing a few prototypes at home to test first will save you money!
Nothing like getting your boards back in the mail to find out you had something wrong with your design!
Image Notes
1. Copper side of PCB for soldering components onto
http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/
step 1: Equipment and Materials
REMINDER: DO NOT use anything metal that will be in contact with the chemicals. You want plastic, plastic, plastic...
Tools:
Dremel
Various sizes of drill bits
Chemicals:
Hardware:
PCB Items
Presensitized PCB board - I purchased from Parts-Express (they have various sizes, and even double sided versions)
3M transparency film for Ink Jet Printers (this is a key component, the surface is textured, otherwise your ink would run off the sheet)
Grafix Rub-onz sheets - I purchased from Hobby Lobby
Image Notes
1. Various size drill bits
2. Dremel and press
3. Crockpot
4. Copper Etchant
5. Positive Acting Developer
6. Nail polish remover
7. Plastic containers
8. plastic measuring cups
9. Sheet of Acrylic to hold your design
10. Daylight fluorescent lamp
Once your design is finished you need to print it out to size. Since this is the bottom side of the PCB, make sure you do a mirror print.
If you are using Eagle Cad, I have attached a zip file containing the CAM print job that will print your files out for you. It will make two .PS files one for the solder side, one
for the component side and will also make your solder side mirrored. Once you have those files, you double click on them and it will make two PDF files that can be
printed.
http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/
Image Notes
1. Example of text and graphics added to PCB through Photoshop. Circuit is still
mirrored.
Image Notes
1. Example PCB file
Image Notes
1. Actual printed circuit board with graphics and text
File Downloads
http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/
step 3: Prepare Your PCB Transparency for the Solder Side
The presensitized PCB board that I used was 4" x 6". My actual circuit is roughly 1.25" x 1.75" so I was able to get a total of 8 boards from one presensitized board.
In Photoshop, I opened up the solder side .PS file and the copied my single circuit design to a new 300 dpi 4" x 6" file. I then laid out a grid, and just copied and pasted
the design over and over to fill in the grid. This gave me a nice even layout to print.
TIPs:
To print. Take the textured 3M transparency sheet and load it into your printer with the white strip going into the feeder. When printed, let it sit for a minute or two to be
sure the ink has dried. Then tape it to the underside of the acrylic sheet.
Image Notes
1. printed transparency taped to under side of acrylic sheet.
2. Text helps to make sure design is facing the proper direction.
When you print, make sure you mirror this image as well. The reason this image gets mirrored is because you will turn the sheet over, and then rub the bottom side
to transfer the image to the top side of your PCB.
Follow the manufacturers directions that come with the Grafix Rub-onz sheets.
http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/
step 5: Exposing Your PCB to Light
The presensitized PCB boards have photo-resist coated on them. The way the process works is everything that you have as black on your design will remain as copper.
The areas that are clear, will be removed by the developer and be left with bare board.
The boards come in a foil wrapping, with a peel of white protective cover over the photo side. It's not necessary but I usually dim the lights a little bit just to be on the safe
side while I am lining up my design onto the board.
Once you are satisfied with how the design is laid out on the PCB board, you can then turn on the natural daylight lamp. I have found that 14 minutes seems to be perfect
timing for exposure with the lamp being 5 1/2 " away. If your lamp is closer or further away you will have to experiment with timing. The manufacturer recommends 10
minutes.
Image Notes
1. Natural daylight lamp
2. Presensitive PCB Board with design and acrylic over top.
3. Timer
To develop the board: place 1 part developer to 10 parts warm water in a plastic container. Gently rock the container back and forth. Everything that was exposed to
light will now wash away leaving you with a copper board and your design on it. Rinse in cold water to stop the developing process.
TIPs:
Use hot tap water, just hot enough that you can touch it and not get burnt. About the temperature you would want to wash your hands with. If its too hot, the entire
design will wash away leaving you with a blank piece of copper board. If too cold, the developing process won't work.
Add the developer to the water before putting your design in. If you pour the developer directly on top of the board, it will immediately wash away
anything it touched.
After developing, if you find any areas where your traces show cracks or areas that seem to light, you can take a black permanent marker and touch up those
areas.
http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/
1. Developed PCB board 1. Developer poured directly onto design. Not good :(
I used my Dremel and a router bit to cut out the 8 circuit boards off my 4"x6" panel. Next you will want to pour the copper etchant into a PLASTIC container and then
gently rock it back and forth until all the exposed copper has been removed.
TIP: This is where the crock pots come in handy. If you use the etchant at room temperature it will take some time to fully remove all the copper. However, if you heat the
etchant up, the process is a LOT quicker.
If you use the crock pot method, make sure you have good ventilation. This stuff smells bad heated, and don't inhale the fumes when you lift the lid of the crock pot!
Make sure you wear latex gloves and old clothes. The etchant will stain your clothes no matter how careful you think you will be.
Image Notes
1. Dremel used to cut out circuit boards, as well as drill holes for component
placement.
http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/
step 8: Applying Graphics to Your PCB
Once your PCB is completely etched wash it with a little soap and water and then drill out your holes for component placement.
Now comes the tricky part. Cut out one of the Component side graphics that you made earlier. You will place this inkside down on the top section of your PCB. (Make
sure both are going the same direction, in my photo they are not. I did line them up correctly but when I took the photo I was holding the rub-onz wrong).
The Grafix Rub-onz are on a light colored material. To make things easier to line up, I used a small light board and laid the PCB down on it. Then when I had the rub-onz
close to the PCB I could see through it which enabled me to line up the holes.
TIP: If you don't have a lightboard... you can take a cardboard box, cut out the bottom, place a piece of plexiglass on top, and a lamp underneath it.
Once you have the rub-on in place, take a Popsicle stick and start rubbing firmly over the back. Peel off paper and your footprint design will be transferred to your PCB.
You could also use a hobby screen printing kit for this process, but that is a whole other Instructable.
Image Notes
1. Graphics rub-onz, PCB and lightboard.
Related Instructables
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Comments
49 comments Add Comment
- Jack -
http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/
Foxau2 says: Apr 5, 2010. 8:45 PM REPLY
When you use the rub onz film, does it apply a continuous film across the entire surface? Or does it only apply exactly what you printed? My question is just,
could I use these rub onz sheets to create my first circuit layout so i don't have to use the photochemical process, instead using this to do something similar
to using a laser printer with photo paper that you iron the design on?
hackaday.com/2009/09/02/direct-to-pcb-inkjet-printing/
Instead of little circles, make little square pads with no holes. Then, snip the legs off some component sockets and solder the sockets to the pads.
After the sockets are tested for conductivity, insert the chips into them. LEDs and capacitors can be soldered directly to the little square pads.
I use the sockets because sometimes I mess up and melt things. Sockets are usually cheaper than the chips. You can make double sided boards this
http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/
way, and connect the two sides with a little hoop of wire, if needed.
The only problem doing it this way, is the glue under the pad can overheat the the trace can lift off the board surface.
I am trying to find some way to use a conductive glue, so I can skip the soldering phase, as it is hot and stinky. I'm not sure if there is a SMD glue or not.
The correct bit isn't really a "drill", it isn't the regular fluted drill bit, it looks more like a router bit (but very small). The flutes on a regular bit are what "pull
up" on the material and might lift the pads. The router bits aren't as efficient as moving the debris, but they don't lift pads either! I got a graduated set of
bits from my local electronics place for $10 or so.
These bits also require high RPMs. Much faster than my drill press can spin. Fortunately the size of the shank matches perfectly to a Dremel tool. The
first few boards I etched were drilled "by hand" just holding the dremel, but I purchased the dremel "drill press" holder since I was doing enough boards to
justify the expense.
Its not too bad actually as far as time concerns. It took me longer to write the tutorial than to actually make a board. I put the attached board together
today, and it turned out nice.
Hi, Folks I use A commercial program lite version PCB3 from England.
I pint the circuit with a laser printer & use Kinsten Positive acting presnsitised board. Exposure by light box useing compact UV flouro tubes for 10 minutes
on a 4 by 4 board. I am in the process of building another light box which will be shallower & have 2 tubes. Etching upuntill this time I have used Ammonium
Persulphate which is slow & has to be heated. This method I have found to be 100% reliable unlike the iron which does not take completely at times.
I also intend to try Hydrogen Peroxide with Hydrochloric acid or solder flux easy to get. This I think was picked up from Instuctables.
Cheers guys Kiwi John
http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/
mikej_w says: Nov 5, 2009. 7:51 AM REPLY
Just a couple of notes:
you have the holes showing on your resist pattern, which is vital to get the drill to center.
Usually you would drill a couple of registration holes on the board before exposing the first side, so that the other side can be placed correctly afterward. I
didn't see how you did that, but you must have because you had good results :)
You can remove all the copper and just leave the traces going from component to component. It all depends on the person. I like to etch less copper
away so I don't have to use up a lot of the chemical.
Likewise, when you design your PCB you could make the area between the traces wider and then you would still etch less copper.
Can you reuse the chemical, ie store it between uses, or you have to use it during that day?
Cheers
I have been looking for a method for using an inkjet instead of laser.
Will have to give this a try and see how it works out.
http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/
_Vyper says: Nov 2, 2009. 9:55 PM REPLY
Yeah the possibilities...
Normally I sandwich two inkjet transparencies together to get enough density. If you align them well, it doesn't effect the process.
There's an ink refill place nearby, I've always wanted to ask them to fill all the tanks in my old carts with a photo quality/UV resistant ink.
I find that printing with 'high quality black' mode, something that mixes all the inkjet colors, gives the best UV resistance. I have to double up like gmoon if I
just use black ink alone.
Put the ink side directly against the PCB for the best exposure. It lessens shadows and light creep through the plastic. With this, print the top mirrored and
the bottom normally.
I use a home tanning lamp directly over the PCB, with everything justified in a picture frame. Exposure time is only 90 seconds with this method.
I print to PDF and then edit in Illustrator so I can position a single tile anywhere on a sheet. I can make 4-5 designs from a single inkjet transparency if I'm
careful about cutting.
Didn't know about the warm developer. I mix a liter bottle and use it at room temperature. Never had a problem with over developing, sometimes I need to
rub tight areas a little to get the mask out (between TQFP100 pins, for example).
http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/
jeff-o says: Oct 29, 2009. 10:51 AM REPLY
Now THIS is something I haven't seen before! Excellent idea!
http://www.instructables.com/id/Creating-Printed-Circuit-Boards-with-a-INKJET-Prin/