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AboutThisInstructable
Posted:
Apr19,2009
8 175.205 views
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incoherent
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Thisinstructabledemonstratestheprocessformakingprintedcircuitboardswith
featuresassmallas0.005suitableforLQFPorQFNICsusingnegativedryfilm
photoresist.Thiswillenableyoutohandlejustaboutanykindofintegrated
circuitavailableevenballgridarray!PicturedareboardswithaTSSOP14,
QFN40packagesusinga.65mmpitchandzeroinsertionforceflexsocketswith
.5mmpitch.
License:
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Step1:Background
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AfterexperimentingwithhomePCBfabbingforawhile,I'vefinallyworkedouta
processthatproducesreasonablyconsistentresultsthatactuallylookpretty
good.Ispentlotsoftimetryingtousethetonertransfermethodwithvarying
degreesofsuccess(OK,varyingdegreesoffailuremightbemoreaccurate).I
alsotriedPhilmore/Dataknegativephotoresistspraywithconsistentlyhorrible
results(thestuffeventuallymeltedthespraynozzlethatcamewithitandleaked
allovertheplace).NotGreen&notrecommended.NowIcouldhavepurchased
presensitizedboardsandsavedalotoftrouble,butIfindthematerialtobetoo
costlyforthevolumeofboardsI'mproducing.Ieventuallytrieddryfilmphoto
resistandIwon'tbegoingback!I'mnotgoingtogointotheintricaciesof
schematiccapture,oretchingsincethosesubjectsarewellcoveredbyother
instructables.Novolatilecompoundsareusedonlysimplebaseswhichcanbe
renderedenvironmentallysafebyfilteringsolidsandneutralizingwithHCl(see
manufacturerinstructionsforproperdisposalprocedures).Thisprocess,when
combinedwithaPeroxide/CupricChlorideetchingprocess
(http://www.adafruit.com/blog/2009/01/25/thechemistryofhomeetchedpcbs/)
formsanenvironmentallyresponsible,GreenPCBdevelopmentprocess.
Ifyouhaven'ttriedthetonertransfermethod,doso.Unlessyouareblessed
withmagicaltonerand/orpaper,thedryfilmresistmethodwillyieldbetter
results,buttheprocessisabitmoreinvolved.Ifyouaresatisfiedwiththetoner
transferresults,byallmeans,stickwiththatmethod.Naturallythestandard
warningsapply:PCBetchinganddryfilmprocessinginvolvecausticmaterials
besuretouseprotectiveequipmentandhaveaneyewashstationhandy(orat
leastabucketofwater).Alsonotethatdryfilmdevelopingandstrippinginvolve
strongbaseskeepthemfarawayfromyouretchingchemicals,ortheymay
reactviolently.
Thusfar,I'veusedthreetypesofdryfilmresist,allofwhichperformedwell:
MGChemicals416DFRDryFilmResist
(http://www.mgchemicals.com/products/416dfr.html)About$20.00for12"by5
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HowtomakePCBatHome
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Home/)
byEngg_suraj
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MakingPrintedcircuit
BoardsatorNearHome:A
ComprehensiveOverview,
AlmostaGui...(/id/Making
PrintedcircuitBoardsator
HowtoAssembleaPrinted
CircuitBoard(PCB)(/id/How
toAssembleaPrinted
CircuitBoardPCB/)
bynkiegrea
ReusingOldPCB's
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byJonathanrjpereira
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HomeBrewPCBs(/id/Home
BrewPCBs/)
byapoorveinstein
(/member/apoorveinstein/)
feetatFrys,Altexandonline.MGrefusedtoquotelargerquantities,andwillnot
divulgethemanufactureroftheirfilm.
DupontRistonM115availableatThink&Tinker
(http://www.thinktink.com/stack/volumes/voli/store/specs/m115spec.htm)
Excellentresist,muchmoreeconomicalthanMGifyouwantlargerquantities
(12"x50ftfor$96.75,12"x100ftfor$116.26).Outstandingoutfit,veryhelpful,
KillerPCBs
byincoherent(/member/incoherent/)
friendlypeopleandlotsofgreatinfo.Terrificsite!
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12Steps
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KolonDryFilmResist(http://dryfilmresist.com/english/introduction.html)
KoreanmanufacturersellsforsomewhatlessthanThink&Tinker'sRiston,but
withaminimumof500ftcases.
Whatyouwillneed
LaserPrinter
Home/OfficeLaminator
LaserPrinterTransparencies
SprayAdhesive
NegativeDryFilmPhotoResist
ResistDeveloper(sodiumcarbonate)
ResistStripper(sodiumhydroxide)
GlassSheets
ClearTape
YellowBugLight
LightSafeArea
Optional
VacuumBagorVacuumFrame
CollimatedUVExposureSource
(http://www.thinktink.com/stack/volumes/voliii/equipment/uvlamp/uvlamp.htm)
Rotarypapertrimmer(http://www.samsclub.com/shopping/navigate.do?
dest=5&item=415940)
21stepStoufferSensitivityGuideforCalibration
(http://www.thinktink.com/stack/volumes/volvi/filmimag.htm#Calibration)
Step2:CreateArtwork
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12Steps
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I'massumingyou'vecapturedyourschematicandlaidoutyourPCBin
somethinglikeEagleifyoudon'tknowwhatI'mtalkingabout,you'dbetterstart
offbylearningschematiccapture(http://www.instructables.com/id/Draw
ElectronicSchematicswithCadSoftEAGLE/),andPCBlayout
(http://www.instructables.com/id/TurnyourEAGLEschematicintoaPCB/).
Onceyou'vegotthePCBlaidout,youwillneedtocreatenegativephotomasks.
Anegativephotomaskisatransparencythatisclearwhereyouwantcopper
andblackwhereyouwanttoremovecopper.Onehint:ifyoumakeahabitof
fillingyourPCBlayerswithgroundorpowerplanes,youwillsavealotoftoner.
Also,notethatyoucantileyourPCBlayoutinEagleusingthegroupcopy
commandifthereisnotanassociatedschematicfile(otherwiseitwillcomplain
youhavetodothisintheschematic").Ifoundtheprocessofinvertingthecolors
inyouroutputtobesurprisinglydifficult,buteventuallyIsettledonthisfairly
simpleapproachusingtheopensourcevectordrawingsoftwareInkscape:
1.Makesureyou'veselectedjustthelayersnecessaryforetching(e.g.
Top/Bottom,Pads,Vias).
2.UseEagle'sprintfunctiontooutputtoaPDFfile.Eventhoughwe'reprinting
ontransparencies,you'llstillwanttomirrorthetoplayersoastoplacethe
printedsideclosesttotheboardandpreventbleeding.
3.Ifyoudon'talreadyhaveInkscape(http://www.inkscape.org/)installed,
downloaditandinstallitnow.
4.OpenthePDFinInkscape(acceptthedefaultloadingparameters).
5.OpentheLayerspane(MenuLayer:Layers).
6.Clickthe+buttontoaddalayer.Nameitwhateveryoulike(Inamedmine
"b").
7.Clickthedownarrowtomovethenewlayertothebottom.
8.Selecttherectangletoolfromthetoolpane.
9.RightclickthebluecolorswatchatthebottomofthescreenandselectSet
stroke.
10.RightclickthegreycolorswatchandselectSetfill.
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11.Clickanddragtodrawanrectanglearoundyourboard.
12.Selectthearrowtool,thenselectanddrageachsideofyourrectangleright
totheedgeofyourboard.Thedisplayshouldlooksomethinglikethis:
13.Rightclicktheblackswatchatthebottomofthescreenandselect
SetFill.
KillerPCBs
RightclicktheblackswatchagainandselectSetstroke.
h(/id/KillerPCBs/)
12Steps
14.Clicktheeyeiconinthelayerspalettetoturnofftheblayer. Collection
15.Clickanddragtoselectyourboard(orclicktheselectallvisibleicononthe
toolbar).
16.Negatetheimage(MenuEffects:Color:Negative)
17.Clicktheeyeiconfortheblayeragain.Youshouldnowhavesomethinglike
this:
18.ClickSaveAs,thenchangethefiletypetoPDFviaCairo,andappend_out
tothefilename(e.g.test_out.pdf)soasnottooverwritetheoriginal.
19.ClickSaveAsagaintosaveasthedefaultSVGformat.
Step3:MakeTransparencies
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Thispartwasabitofachallengetoo.Theproblemisthatmostlaserprinters
don'tmakereallydarkprints,sosomelightleaksthroughtheblackareas.Itried
lotsofapproachestoselectivelydarkenthetoner:dryerasemarkers,stamp
padink,crayons,charcoal,graphite,softening/heating+additionaltoner
application,etc..Noneofitworked.Here'swhatworksconsistentlyforme:
1.StartwithsmallartworkIusearotarypapertrimmertocuttransparency
sheetsintoquarters(4.25x5.5)23sheetsatatime.Smallartworkisbetter
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becauseheatrelateddistortionsinthetransparencymaterialwillbereduced.
2.OpenthePDFfromthelaststepwithAdobeReader,andprinttoalaser
printerloadedwithyourtransparencysheets.Formyprinter(BrotherHL
5250DN)Iusethefollowingsettings:Userdefinedpapersize(4.25x5.5),no
duplex,manualfeed,1200dpi,DarkestDensity.Bighinthere:Youcanhave
multiplecopiesofthesameprinterinstalledintheWindows,soaddanew
printercalledPCB_Laserasaduplicateofyourexistinglaserprinter,thenright
KillerPCBs
clickandmodifythedefaultsasneededforPCBtransparencyprinting.
h(/id/KillerPCBs/) 12Steps .
3.Printtopandbottomartwork.Holdtheartworkuptothelight:Doyouseeany
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lightseepingthroughtheblackareas?Ifyourresultsaresimilartomine,youwill
haveenoughseepagetocauseproblemswithyourresist.Notethatyoureally
needtohavesomelargerblackareastoaccuratelyjudgetonerdensity.Ifyou
areblessedwithsuperdensetoner,thenskiptostep8,otherwise,goahead
andprintasecondcopyofeachofyourtransparencies.
4.Nextyouneedamakeshiftlighttabletoaligntheartwork.Thiscanbeas
simpleasapieceofpapertapedonasunlitwindow,orashallowtraycontaining
ahockeypucksizedlightcoveredbyasheetofpaperandapaneofglass.The
backlightfromascannermakesagreatlighttable.Justrunascanin
transparency/negativemodechancesareitwillleavethebacklightonfor
severalminutesafterscanningthenremovethelidandflipitover.Theuseofa
headmountedmagnifyinglenswillhelpsignificantlyinaligningyourartwork.
5.Nextwewillbondthetransparencypairs(2xtop,2xbottom)todoublethe
tonerdensity.Todothis,takeonecopyofeachtransparencyandapplyspray
adhesivetothetonerside.Youcantellwhichthetonersideisbyobservingthe
reflectionoflightoffthesurfaceofthetransparencythetonerappearsdullon
thetonerside.
6.Placethenonadhesivecoatedtransparencytonersidedownonthelight
tableyoumaywanttolooselytapethecornersofthissheettothelighttable
(foldthetapeoverattheendsoyoucaneasilypealitupafterward).
7.Carefullyalign(register)theadhesivecoatedtransparencywiththeuncoated
transparency.Oncealigned,pressfirmlytoadherethetwosheets.
8.Passthealignedtransparenciesthroughthelaminatoronthecoldestsetting
topermanentlybondthelayerstogether.
9.Alignthetopandbottomartwork(tonersidein)andtapesecurelyleaving
enoughroomtoslidethePCBbetween.Alternately,ifyouhaveaborderthatis
atleastanincharoundtheboard,youcanapplysprayadhesivetoa1/2"strip
alongtwoedgesbycoveringtherestofthemaskwiththecornerofapieceof
paperjustbesuretonolessthan1/4"betweentheadhesivestripandtheedge
oftheboard.
Step4:PrepareCopperClad
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Carefullycleanthecoppercladmaterialwithascrubbingpadandableach
containingscouringcompound(e.g.SoftScrubw/Bleach).Sandwith320or400
gritwet/drysandpapertoroughenthesurfaceandensureproperresist
adhesion.Drytheboardbeingcarefulnottotouchtheboardwithoutgloves(to
preventtransferringskinoilstotheboard).
Step5:Laminate
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ThereareafewdifferentpossibleapproachestolaminatingthePCB.MG
Chemicalssuggestsafolderoverandlaminateapproach.Otherssuggestusing
eitherheatorwater(orboth)toadheretheresistmaterialtothePCBpriorto
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lamination.I'vehadgoodluckwiththisapproach:
1.Makeyourworkarealightsafe:Turnonthebuglightandturnoffany
fluorescent,or>40Wattincandescents
2.Cutlaminatematerial1/2inchlargerthanboard(doublethelengthifyouare
doingadoublesidedboard)
3.Carefullypeeljustbackjustthefirsthalfinchoftheinnerfilm(alwaysonthe
insideofthecurl)
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4.Carefullyalignthelaminateensuringthatthelaminatecoverstheboard
completelyonbothsides(ifdoublesided).
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5.Pressthefirsthalfinchofexposedlaminatetotheboard.
6.Carefullypulltheremaininginnerlayerdownwardahalfinchatatime,while
simultaneouslypressingtheexposedlaminatetotheboard.Becarefulnotto
introduceanywrinkles.Continuetothebacksideinasimilarmannerif
necessary.
8.Passtheboardthroughthelaminator(oncethelaminatorisfullyuptotemp).
Flipoverandpassthroughthelaminatoragain.
Step6:Expose
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PlacethelaminatedPCBbetweenthepreregisteredtransparenciesandtape
securelyinplace.TapeaStouffer21stepsensitivityguideoveranopensection
ofPCBifyouplantocalibrate
(http://thinktink.com/stack/volumes/volvi/filmimag.htm#Calibration)your
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exposureprocess.YouwanttopresstheartworktightlytothePCBtoprevent
lightfromleakingunderyourtraces.Youcandothiswithtwosheetsofglass,or,
preferably,youcanuseavacuumbag,orvacuumframe.Youcanthenplace
thisassemblyinbrightsunlightforabout58minutesperside,oruseanother
UVsourceofyourchoosing.Notethat,despitethetightfitofPCB&artwork,
collimation(makinglightraysparallel)isimportanttoachievefinetracesrefer
here
KillerPCBs
(http://www.thinktink.com/stack/volumes/voliii/equipment/uvlamp/uvlamp.htm)for
instructionsforconstructingacollimatedUVlightsource.
Collection
Step7:Develop
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Followthemanufacturer'sdirectionsforpreparingdevelopersolution(usually
SodiumCarbonateorPotassiumCarbonate)anddevelopingyourboard
(developingremovesresistnotexposedtoUVlight).
Step8:Etch
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Useyourfavoriteetchantjustmakesureyougivesomethoughttofuture
disposalandconsideragreenprocesssuchasPeroxide/CupricChloride
etchingprocess(http://www.instructables.com/id/StopusingFerricChloride
etchant!Abetteretc/)(itisliterallygreen,too).And,ifyouwanttodigintothe
nittygrittydetailsofthechemistryinvolved,thispage
(http://members.optusnet.com.au/~eseychell/PCB/etching_CuCl/index.html)is
foryou.
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12Steps
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Step9:Strip
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You'llneedsodiumhydroxide(NaOH)forthisthisisthestuffthatBradPittuses
toburnEdwardNorton'shandinFightClub
(http://www.imdb.com/title/tt0137523/)itdissolvesfat,andyourskinis
composedlargelyoffat,sobecareful.ChecklocalchemicalsupplyhousesI
luckedout:myneighbormakessoap,soIjustpoppedoverandaskedifIcould
borrowacupoflye!
Step10:SolderMask&SilkScreen
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Applysoldermaskbyscrubbingandrelaminatingetchedboardwithanew
layerofresist,thenremovetheprotectiveouterfilmandapplyasecondlayerof
resisttodoublethethickness.Nowexposewithstopandsilkscreenlayersand
developasbefore(exposuremaytakeslightlylongerduetoextrathicknessof
resist).Bakeintoasterat200220degreesFforabout10minutes(beingsureto
propuptheboardsothattheresistwon'tsticktothetoaster).Removetheboard
fromthetoasteranduseawhitecrayontofillinthesilkscreentextwhilethe
boardisstillwarm.Wipeanyexcesscrayonwaxoffwithatowelandusea
toothpicktoremoveexcesswaxfromgroovesandtraces.
Step11:SolderPasteStencil
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12Steps
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Ifyou'vegottenthisfar,youmusthavepulledafewlatenightsandconsumed
copiousquantitiesofcarbonated(andcaffeinated)beverages.Ifso,graboneof
thosesodacansandcutthetopandbottomoffwithapairofscissorsorlight
shears.Trytocutitneatlywithoutraggededges.Nextcutlengthwisetoproduce
astripofaluminumabout8"by4".Thisstripwillbeverycurly,butyoucan't
"unbend"itwithoutmakingwrinkles.Forthefollowingsteps,youcaneitherdeal
withthecurl,oryoucanannealthemetalbyheatingitinatoasteroventoabout
450degreesFthenletitcoolslowlybackdown.Nextyoumustsandboththe
insideandoutsideofthecanwith220to320gritwet/drysandpapertoremove
thepaint(notethatthereisclearpaintontheinsideofthecanotherwisethe
sodawouldeatthroughit).Youcanusesomeheavydutypaintstripperforthis,
butsandpaperseemsabitgreener.Onceyou'vegottenallthepaintoff,scrub
wellwithSoftScrubwithBleachtoremoveeverytraceofoil.Nextlaminate
photoresistonbothsidesjustlikeyoudidwiththePCB.Makeyourartwork
usingthetcreamlayerasyoudidbefore,butdon'tmakenegativesthistimethe
outputofEagleisalreadyanegative!Besuretomaketwotransparencieseach
forfrontandback(andbesuretomirrorthefrontsothetonerwillberightup
againsttheresist).DevelopasbeforeandetchindilutedHCl.IdilutedtheHCl
toabout50%(pouracidintowater,nottheotherwayaround).Etchingwillstart
slowlyuntiltheoxidelayerhasbeenremoved,thenspeedupsignificantly.Don't
etchtoofast,ortheboardwillheatupandtheresistwillcomeoff.Ifyouleave
theresistinplaceyou'llhavea~5milstencil,oryoucanstriptheresisttogeta
~2milstencilbutbeware,NaOHwillattackthealuminumwithjustabitless
tenacitythantheHCl(dependingonconcentrations).Nextuseyourfailed
boards(youshouldhaveafewofthesebynow)torigupasolderpastejig.
Applythesolderpastewithapaintscraper,orsimilar,placeyourparts,andget
onwiththereflowing...
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Step12:Reflow
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12Steps
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Prettysimplestuffhere:Heatuntilsolderpastemelts,thencool.Besuretouse
afairlystoutcopperoraluminumplatetoevenlyspreadtheheatacrossthe
board.Onceallthesoldermeltstakethemetalplateoffthehotplate,andplace
itonaheatsinktobringthetempbackdownquicklycementgaragefloorswork
greatjustmakesureyouuseovenmits(butdon'tbakecookieswiththem
afterwards...).Youmayneedtocleanupsomebridgedconnectionsafter
reflowing.Forthis,justusesolderwickandlotsofflux(IlikeOrangeCrush
(http://www.precisealloys.com/orangecrush.html)).Applypowerandfireitup!
BTW,Iaccidentallyranthetempuptoohighonthefirstboardandgotthecool
gradientcoloreffectonthesoldermaskasaresult(seetheintropic).Ithinkthe
componentswerestillinspec,butIdidn'thaveagoodheatspreaderunderitat
thetime,soIcan'tbesuretheprobewasreadingthesametemptheboardwas
seeing.TheboardseemsOKsofarthough...
Wellthat'siteasyeh?Besuretowatchformyupcomingwebsite
IncoherentLabs.com.Nowhavefunandgosavetheworld!
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Pleasebepositiveandconstructive.
wIMadeit!
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12Steps
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3yearsago
IMadeit!
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ApplyingthedryfilmisTHEhardestpartoftheprocess.I'vetriedanumberof
methods,andhereisthebestoneformesofar,usingalaminator.
1.Cleanboardveryclean,asdescribedalreadyhere.
2.Preparea"carrier",Itakeapieceofthinflatstiffcardboardsuchasa
breakfastcerealbox,Iplacetheboardinthemiddleofthecardboard,andat
eachoftheboard(thetopandbottomasyouwouldfeedittothelaminator)I
stickdownapopsiclestick(orsuchlike)ontothecarrierwithdoublesidedtape
toform"endstops",tokeepthecircuitboardfrommovingasthelaminatorfirst
bitesit,imagine[stick][board][stick]thesticksmustbelongerthantheedge
theyarebuttedupagainst.
3.Itakeapieceofdryfilm,cutsothatthereisabout5mmextraallaround(or
atleasttopandbottom).Iplacethefilmcurlsidedownontopoftheboardso
thatitcoverstheboardandthe5mmateachendoverlaptheedgeofthe
popsiclesticks,thenIputapieceofsellotapeoveroneendofthefilmtostickit
tothepopsiclesticktomakeahingeacrossthetopedgeofthefilm.
4.Itakeanotherpieceofcardboard(widerthanthefilm),andItapethattothe
otherendofthefilmtomakea"tail"fromwhichyoucanholdthefilm.
5.Foldthefilmoverbackwardsusingthesellotapeatthetopasahinge,now
stickapieceoftapeonacornerofthebottom,andseparatethelower
protectionlayer,removingitcompletely.
6.Holdingthecardboard"tail"youattached,liftthefilmupvertically,andthen
feedyourcarrierintothelaminator,loweringthefilmbythe"tail"asthe
laminatorjoinsittotheboard.
That'sit.Soundscomplicated,butitmakesitMUCHeasiertogetagoodclean
bond.Runitbackthroughthelaminatoracoupleoftimesifyouthinkit's
necessary(experimentwithyourlaminator).Don'thavethelaminatortoohotor
thefilmcanbedamaged,andlikewisetoocoldmightnotbondwell.
Onceyou'vemadethecarrier(allof2minutes)youcanofcoursereuseitfor
thesamelengthofboard.
Leavethebondedboardinthedarkforagood10or15minutesbefore
exposingit,toallowittocoolandthebondtostrengthen,theUVpolymeris
quitesoftwhenwarm(whichiswhyitneedstobewarmed,sothatitconforms
totheboard'smicroscopiccontours).
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MatthieuR(/member/MatthieuR) . sleemanj(/member/sleemanj)
(Yes,I'mreplyingtoa3yearsoldpost).
Reply
4monthsago
Iuseasilmplehairdryer!Itworksfine.
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wi10008(/member/wi10008)
3yearsago
Anotheroptionfordarkeningtransparenciesistouseablackdryerasable
Reply
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marker.Colourintheentiresheetwiththeerasablemarkerandallowtodry.
Wipeoffagainwithsofttissue.Theinkremainstrappedbetweenthedotsofthe
laserprintbutwipesawaycleanlyeverywhereelse.
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. wi10008(/member/wi10008)
KillerPCBssanosuke_kursch(/member/sanosuke_kursch)
2yearsago
Youalsocanuseacetonevapourtomelttheplasticof
Reply
thetonersoitwillspreadmoreevenly.
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Tapethesheetunderthelidofatupperwareorsomethingofthesorts,put
someacetoneinthecontainer,putthelidandletitsitforsometime,then
removethesheetfromthelidandcheckitagainstalightsourcetosee
howmuchitdarkened.
Flag
2yearsago
Reply
ThedoublesidedA4sizeglossphotopaperIgetfromASDAWalmarthasno
watermarks.Irecentlyboughtasingle10WUV380nmLEDfrommouser.com
andthisonlyworkswithtransparencies.Myglosspaperfluorescesat380nm
butisfineat395nm!
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3yearsago
Reply
I'vejusttriedprintinglaserprintonglossphotopaperandplacingprintdirectly
againstphotoresist.Ileftthepaperglossy,withoutapplyingoilseven.Then
exposedasnormal.Thisgivesmuchbetterresolutionthantransparencies!The
laserprintercangetalotmoretonerdownatahottertemperatureongloss
paper.IfthetonerisdirectlyagainsttheboardanyscatteroftheUVhaslittle
effectontheresolution.
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martshal(/member/martshal) . wi10008(/member/wi10008) 2yearsago
Reply
Don'tmostphotopapershavewatermarksacrosstheback?Didyouhave
tosearchforaspecificbrand?
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3yearsago
Reply
RegardingthedoubleprintmethodtogetadarkermaskI'vefoundthata
numberofwebsitesrecommenda"tonerdarkerner"or"toneropacifier"spray.
Someforumssaythatthisisjustaclearacrylicsprayssuchas"KrylonAcrylic
CrystalClear".
Apparently,thelaserprintissprayedwiththeacrylic/solventandthenrolled
withasmoothroller.Thesolventsoftensthetonerandthepressingspreadsthe
dotsoftoneroutslightlyfillinginthegaps.Thesolventisthenallowedto
evaporateleavingaverydarkprint.Iintendtotrythissoon.
Thanksfothegreatwriteup!
Flag
sleemanj(/member/sleemanj)
3yearsago
Reply
I'dliketoadd,thatinmyrecentexperimentswithdryfilm,Ididn'tuseSodium
Hydroxidetostripit,IjustdroppedtheboardintheSodiumCarbonatesolution
whichIhadusedto"develop"it,andwhenIcamebackinaboutanhourorso,
alltheresisthadsimplyfloatedofftheboard.
Favorite
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IexpectthatSodiumHydroxidewouldworkprettymuchinstantly,butifyoucan
waithalfanhour,thereseemslittlepointmessingwiththat.SodiumCarbonate
(WashingSoda)isperhapsmorereadilyavailablethanSodiumHydroxide
(althoughbothareprettyeasytocomeby),thestuffIboughtwassoldasa
"naturalfabricsoftener"andis100%SodiumCarbonate,justlookonallthe
packetsoflaundrysuppliesinyoursupermarket,there'ssuretobeonehiding
theresomewhere.
Fordeveloping,about5minutesisthelongestIwouldleaveitinthesolution,
longerthanthatanditrisksdamagingthetracestooeasily.Don'tusea
IMadeit!
Collection
scrubbingpadoranythingabrasive,thetracescanbedamaged,justuseawad
oftoiletpapertofirmlywipetheboardafterit'ssoakedacoupleofminutes.
Thehardestpartofthisprocess,isgettingthefilmontotheboardevenly,
withoutanytrappedbubblesorwrinklesordust,andthengettingitthroughthe
laminatorwithoutitslipping.
NB:Ididn'tparticularlymeasuretheamountofSodiumCarbonatecrystalsI
dissolved,soyourmileagemayvary.
Flag
robielyn(/member/robielyn)
4yearsago
Reply
Nicewriteup!
Ihaveaquestionthough.Sincethisisa"negative"processtheblackareason
thephotomaskaregoingtobecopperfreeareasontheboard.Tonerdensity
problemsoccurinthecentralportionsoflargeblackareas.However,theseare
theplaceswherecopperisgoingtoberemovedandI'mwonderingwhat
differencedoesabitof"speckling"inthecopperfreespacesmakesincethere
isnochanceitwillcauseshorts.Theclearareasofthenegativewillbethe
variousfootprintsandtraces.Thespacesbetweentraceswillbeverynarrow
linesandthelaserprintercandealwiththatwithnodifficulty.
ItseemslikeI'mmissingthepointofwhyyouaregoingtoalltheworkof
makingtwocopiesandgluingthemtogether.Canyouhelpmeoutwiththis?
Flag
X
8
purpulhaze(/member/purpulhaze)
4yearsago
Reply
Niceinstructable.Igotsomegoodpointersonmakingmyownpcbs.Ihavea
quickquestion.Howdoyoucutyourpcbs?
I'venotbeenabletogetareallycleanstraightedge.Iusearotarytoolwithcut
offwheelbuthavealsotriedusingahacksaw,scoringandtinsnipsbutcan't
getacleanedge.I'vebeenthinkingaboutpurchasinganoldheavydutypaper
cutting,wettilesawor8"metalshear(linkbelow).
Whatdoyouuseorthink?
http://www.northerntool.com/shop/tools/product_200309554_200309554?
cm_mmc=Googlepla_Metal%20Fabrication_Benders
_143363&ci_sku=143363&ci_gpa=pla&ci_kw={keyword}
Flag
Culturedropout(/member/Culturedropout)
4yearsago
Reply
Hi.Firstoff,yourInstructablewasveryinformativeandusefulthanksforallthe
workthatobviouslywentintoproducingit.I'vebeentestingsomeofthesame
(orverysimilar,Ibelieve)etchresistfilmyouhave,withtheideaofetchinga
brassplaqueafterexposingitthroughapairofidenticallaserprinted
transparencies(forbettercontrast).Aftertwoorthreefailedattempts,Ifound
thatthrowingthewholethinginaziplockbagandzippingitshutonthenozzle
ofmyshopvacworkedprettynicelytokeepeverythingtighttogether,andafter
Favorite
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seeingsomesortofbandingorstripingintheexposurewhenItrieda
fluorescentblacklighttubeabout10"abovethetarget,Iendedupjusttossingit
outthebackdoorintothesunlightforabout10minutesandthatseemedto
workprettywell.Imayhavetoexperimentmorewithexposuretime,butit's
startingtogetprettyclose.
ThepointwhereeverythingwenttoheckwaswhenItriedusingthistechnique
KillerPCBs
tosaltwateretchthedevelopedbrassplaque.Theresistfilmprettymuch
boiledoffthesurfaceofthebrassafterafewminutes,seemingtostartaround
theexposedbrassareasleftafterdeveloping,andbubblingoutfromthere.
IMadeit!
Collection
So...amItoconcludethatthisparticularfilmisnotsuitableforsaltwater
electroetching?Istherepossiblyadifferentkindthatmightbe?Thearticleon
electroetchingusesaCNCcutvinyldecalastheetchresist,soI'msureit'sa
lotthickerthanthefilmI'musing.Doyouthinkthat'stheissue,ordoesthesalt
waterbreakdownthisfilm?Ifso,what'stheleasttoxicetchantyoumight
recommendthatwouldworkwellwithbothbrassandthisfilm?Any
suggestionswouldbemostappreciated.Thanks!
Bill
Flag
ffsman(/member/ffsman)
5yearsago
Reply
alternatemethodusedinINDIA:
goto:filemenuinEagle
select:Export
thenselect:image
AdialogboxappearsaskingwheretostoretheIMAGEofyourboard
tick:monochrome
(changeresolutionifyouwantorleaveittodefaultvalue)
Select:browseandthensaveyourimagefile
theimagesavedispositiveimage
locatethefile
openitusingpaint
press:ctrl+i>thiswillconvertpositiveimagetonegativeimage
thensaveit
Flag
c14nz(/member/c14nz)
6yearsago
Reply
*howmuchNa2OH3(sodiumcarbonate)solutionshouldbedilutedin500mlof
water?NaOH(IknowthatPeakOutcontaining30%NaOH)isnotgoodfor
developmentoristoostrong(Ihaveseno4007butIdon'tknowifit'sgoodfor
thistypeoffilm,Iknowit'sgoodforsprayPositiv20)
*canyoutellmeinwhatproductscanbefoundNa2OH3
thanks
Flag
FrozenFire(/member/FrozenFire) . c14nz(/member/c14nz) 5yearsago
Reply
Na2OH3doesn'texistifyoumeansodiumcarbonate,that'sNa2CO3.
Washingsoda.Chancesareyoursupermarketsellsit.
Flag
X
8
mrwolfe(/member/mrwolfe)
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6yearsago
Reply
Ifindthatawaxprinter(e.gtektronixphaser)oracolour
laser(e.gHPlaserjet1600)givesprettygooddensity.
OrdinaryblackandwhitelaserprintersareOK,butyouhavetoturnthedensity
upasfarasyoucan.Eventhenyoustillgetpinholes.
Flag
GM2009(/member/GM2009)
h(/id/KillerPCBs/)
6yearsago
12Steps
.
Reply
thanks
IMadeit!
Collection
IdidmyfirsttworunsstepthatIthoughtiseasiest(laminating)provedtobe
mostdifficult...fornow.I'veusedUVledbox,exposure34minutes,drain
cleaner1:20dissolvedinwater,everythingwasfineexceptlaminating.
Ihadalotof,asyousay,blisters.Laminatorissameasoneonthepicture
(soverign).Ididn'tseeyourreplysoI'vetriedsetting7and5andbothwere
bad.
Iamlaminating0.05brasssheet,notmakingpcb,soMGmethod(overlapping)
cannotwork.
NowIwilltrytorunmachinecoldandthatwillprobablyhelp.Thefactisthat
filmhastoadheretocopperperfectly.Anyimperfectionwillruingetching(dust
etc.).
Workingwithcoppercladisprobablyeasierthanthinbrasssheetbutaswith
everythingnewpracticehelps.
Flag
X
8
incoherent(/member/incoherent)(author) . GM2009(/member/GM2009)
6yearsago
Oops,Iaccidentallyrepliedtomyselfbelowsobe
suretoreadthatfirst!Forgottomentiononemorestepalso:
Reply
Pressalltheexcessmaterialtogethertocompletelysealit.Thentrimwith
scissorstobesurenouncoveredmaterialisexposedasthiswillstickto
thelaminatorrollers.
Finallyrunitthroughthelaminatoronthecoldsettingtwoorthreetimes.
Goodluck,
incoherent
Flag
X
8
incoherent(/member/incoherent)(author) . GM2009(/member/GM2009)
Here'smyadvicebasedoncountlessroundsof
laminating/etching:
6yearsago
Reply
Firstputonglovesandeliminatealltracesofoilfromthesubstrateby
scrubbingwithsoftscrubw/bleach,thendryquicklywithanaircompressor
toavoidoxidationasmuchaspossible.Donottouchthesubstratewith
barehandsfromhereout.Iswitchfromdishglovestosurgicalglovesat
thispoint.
Next,cutthephotoresisttoasheetlargeenoughtocoverthefrontand
foldovertotheback(thelongwayifnotsquare)with1/2"extraall
around.peelbackjustthefirsthalfinchofthecovering(thedullsideon
theinsideofthecurl).Laythematerialovertheboard,makingsurethatit
issufficientlyalignedtowraptothebackwithoutveeringofftheboard.
Useyourthumbstopressthe1/2"exposedsectiontotheboardevenly
startingatthemiddleandslidingtowardsthesides.Iftheboardistoo
cold,thiswon'tstickwell,butatabout80degreesF,itwillstickquitewell.
Unlessyou'reinanigloo,thisshouldbenoproblem.
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Onceyou'vegotthefirst1/2"adhered,turntheboardaroundsothatthe
adheredportionisfacingyouandthestillcoveredfilmisfacingawayfrom
you.Pullthefilmbackonemore1/2"betweentheboardandthefreefilm.
Carefullypressthefilmtotheboardstartingatthemiddleandworking
outtotheedgebeingsuretoavoidbubbles.Repeatthisprocess1/2"ata
timeuntilthefrontofboardiscovered,thenfliptheboardanddothe
KillerPCBssameonthebacksideoftheboard.
h(/id/KillerPCBs/)
12Steps
Substratetemperatureispivotallessthan~75degreesF,anditdoesn't
IMadeit!
Collection
stickwellenoughandbubblescreepbackinafteryoupressthefilm
down.Ifthetempis~90degreesFormore,itwillsticktoostrongly
withoutevenpressing,andmaystickprematurelyandentrapbubbles.
Hopeallgoeswell.BesuretopostpicsisyourUVLEDboxfeaturedin
oneoftheotherinstructables?
Flag
X
8
incoherent(/member/incoherent)(author)
6yearsago
Reply
Frankly,I'vefoundthatitworksbestcoldanyheatatall,andIgetasortof
blisteringhereandthere.
Flag
6yearsago
Reply
Whatislaminatorsetting(temperature)?Thanks.
Flag
UltraMagnus(/member/UltraMagnus)
7yearsago
Reply
thatdoesn'tlooklikeaPCBdoneineagle,whatprogramdidyouuse?
Flag
X
8
incoherent(/member/incoherent)(author) . UltraMagnus(/member/UltraMagnus)
7yearsago
Yes,IdiditinEagleexceptforconvertingtonegatives
thatwasdoneinInkscape.BTW,whichpartlooksnonEaglelike?
Reply
Flag
UltraMagnus(/member/UltraMagnus) . incoherent(/member/incoherent)
Iguessthecurvynessofthetracksthrewmeoff.Itakeityou
didn'tusetheautorouterthen?
Reply
7yearsago
Flag
X
8
incoherent(/member/incoherent)(author) . UltraMagnus(/member/UltraMagnus)
7yearsago
Reply
Ican'tstandtheautoroutermaybeI'mjustdoing
somethingwrong,butIneverseemtogetmorethanafewwiresrouted
beforeitquits.I'dliketotrytomakeanautoroutermyselfsomeday,but
that'sabigjob...
Flag
josheeg(/member/josheeg) . incoherent(/member/incoherent)
Reply
6yearsago
Iusedeagleautorouterandkicadwithfreeroute.
Bothifthewiresaresmallenoughtomakeitandthegridtheroutingis
doneonissmallenoughandtheirisenoughroomitdoesitfreeroute
maytakeawilebutmylinuxcomputerlaptopwasdated.
Favorite
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Flag
perkinsb1024(/member/perkinsb1024) . incoherent(/member/incoherent)
7yearsago
Reply
Stayfar,farawayfromautorouter.Itwillneveryieldthe
resultsthatapatienthandandclevereyewill.I'veneverlikedthecurvy
KillerPCBslinesthough,Iusethe45degreebendlines
h(/id/KillerPCBs/)
12Steps
Flag
Collection
X
|
8
pfred2(/member/pfred2) . perkinsb1024(/member/perkinsb1024)
IMadeit!
Reply
7yearsago
PersonallyIratherlikeEagle'sautorouter.Somecircuitsare
affectedbysharpcorneredtraces.Idoubtcircuitsmuchcarewhatyou
likeornot.
Flag
UltraMagnus(/member/UltraMagnus) . pfred2(/member/pfred2)
Reply
7yearsago
don'tknowwhatproblemsyoupeoplehavehadwiththe
autorouter,butIhavefounditworksfineonceyoufiddlewiththesettings
alittle.
Flag
X
|
8
pfred2(/member/pfred2) . UltraMagnus(/member/UltraMagnus)
Reply
7yearsago
Theautorouterhasworkedfineforme.Ihavedonesome
complexboards,singlesided,withhardlyanyuncompletedtracesusingit.
AnyonehavingtroubleswithEagle'sautorouterisnotusingtheprogram
correctly.Therearetutorialsavailablethatteachhowtheprogramworks.I
haveusedthemmyselftolearnaspectsoftheprogramthatIdidnot
understand.ThoughIhavetosay,learninghowtomanipulatetherouting
ruleswasn'toneofthem!
Flag
X
|
8
pfred2(/member/pfred2) . incoherent(/member/incoherent)
7yearsago
Reply
IneverhadaproblemwiththeautorouterinEagle.Inevermaketoo
challengingboardsthoughIguess.Idorememberonebugwithfilling
landsintheprogramthough.Iwonderifitevergotfixed?
Flag
dynaco(/member/dynaco)
7yearsago
Reply
thatsperfect.Butwhyyoudontexplainthedrillingprocess?
Flag
|
8
Sandisk1duo(/member/Sandisk1duo) . dynaco(/member/dynaco)
itisn'tneeded,everythingissurfacemount
Reply
7yearsago
Flag
SuperFungus(/member/SuperFungus) . Sandisk1duo(/member/Sandisk1duo)
6yearsago
Reply
Ithinkhewasreferingtoviaswhicharecommonly
usedevenonsurfacemountboards.Theseareholeswhichgobetween
layersofapcbtocarrysignalsfromonelayertoanother.Inanormalpcb
processtheseareplated,itseemswiththeprocessdescribedhereyou'd
needtomanuallysolderinconductorstomaketheviaswork.
Favorite
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Flag
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8
incoherent(/member/incoherent)(author) . dynaco(/member/dynaco)
Reply
7yearsago
Wow,Itotallyspacedthat!!Yeah,therearelotsofholes
requiredforviasandafewthroughholecomponents.I'llhavetoadda
KillerPCBspageondrilling.Thanksforthereminder!incoherent
h(/id/KillerPCBs/)
12Steps
Flag
Collection
dynaco(/member/dynaco) . incoherent(/member/incoherent) 7yearsago
IMadeit!
Reply
ifyouusesomekindofchemicalviametalisationpleaseexplainittoo.
Andofcoursetheminimumdiameterofholes=)
Flag
X
8
incoherent(/member/incoherent)(author) . dynaco(/member/dynaco)
Reply
7yearsago
I'veattemptedelectrolesstinplatingusingPhilmore/Datak
Tinnitwithresultsalmostasdisastrousaswiththeirsprayonresist.Isaw
aHowtositethatusedMG'selectrolesstinplating,butIhaven'ttriedityet
(andIcan'tfindthesiteatthemoment).Thissite
(http://www.technick.net/public/code/cp_dpage.php?
aiocp_dp=guide_pcb#2)isworthlookingatinthemeantime.
Flag
X
8
incoherent(/member/incoherent)(author) . incoherent(/member/incoherent)
7yearsago
Here's
(http://www.instructables.com/id/DIY_Printed_circuit_board/)the
instructablethatusesMG'selectrolesstinplatingsolution.
Reply
Flag
|
8
ReCreate(/member/ReCreate) . incoherent(/member/incoherent)
Reply
7yearsago
Wow,whereisyouravatar?
Flag
|
8
ReCreate(/member/ReCreate) . ReCreate(/member/ReCreate)
Likethis
Reply
7yearsago
(http://cdn.instructables.com/F15/7Q96/FU4TCPJ9/F157Q96FU4TCPJ9.LARGE.jpg)
Flag
X
|
8
jeffo(/member/jeffo)
7yearsago
Reply
Hmmm,Iwonderifyoucouldusegalvanic(akaelectrolysis)etchingforthis
step...
Flag
drleavsy(/member/drleavsy)
7yearsago
Reply
Isuggesttouse100200UVLED(12Vpowersupply)intheformofarrayasit
Favorite
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wasdescribedinhttp://www.instructables.com/id/Howtomakeaprintedcircuit
boardPCBusingth/(http://www.instructables.com/id/Howtomakeaprinted
circuitboardPCBusingth/),thenthereisnoneedtotakecareabout
collimationandaboutfragiletubesandstuff.Ibelievethetimeofexposurecan
bereallyshortabout1minasitdescribedinaforementionedsource.
Flag
h(/id/KillerPCBs/)
12Steps
.
7yearsago
Reply
IMadeit!
Collection
IhaveSamsungML2510andprintingontransparentfoilwasnotsogood(not
denseandvisibleprintinglinestonerwasquiteused).Alsotriedmyoffice
printer(prof.quality).Itproducedveryuniformblack(freshtoner)butnotdense
enough.Twofoilwouldbejustperfect.VerygoodoutputwasproducedwithHP
C5580InkJetprinter.Used1200dpiresolution,grayscale,BlackInkOnly,Ink
Volumeheaviest.Resultisreallygood,sharp.Doubleoverlappingfoilisnot
needed.Printerisbrandnewthough,Idonotknowifresultwillchangeoverthe
time.Stilldidn'tfinishcompleteprocess.EtchingisnotusedforPCB(even
thoughImightlater)butforBrassetching(modelphotoecthedparts).Idonot
knowifotherInkJetswillproducegoodresultto.Somebodyelsecanaddmore
tests.Selectionofprintersiskindoflimited.Forexample,manyEpsonmodels
willnotprintontransparencyanymore(printerwillnotrecognizemedia).Most
ofHPprintersdoprintonfoil.MostofCanonprintershavelimitedB&W
resolutionof600x600dpi.Notgoodenoughforfinework.AsforetchingIused
PeroxideandMuriaticacidfortest.Whenitwasfreshitwasfinebutafterone
dayitseamslikeitisnotstrongenough?Etchingbrassof0.10.3mmthickness
ismuchslowerthancoopercladCBanditisbitmorecomplicatedsincetwo
sidedetchingisrequiredandsometimesembossedaswell.
Flag
JoeyJunior(/member/JoeyJunior)
7yearsago
Reply
Nicejob.Onequestionthough,whydidyouusecurvedlinesinsteadof45
degreeangles?
Flag
X
8
incoherent(/member/incoherent)(author) . JoeyJunior(/member/JoeyJunior)
7yearsago
Reply
Justforfunreally.I'vebeentoyingwithwritingan
autorouterusingaspring&dampermodellikethatusedinGraphviz
(http://www.graphviz.org/).Curveylinescanbeappliedtoaccommodate
obstructions,frequency/EMsensitivityincreasestension,etc..Thateffort
isawaysdownthelistrightnow,though...
Flag
mikeg103002(/member/mikeg103002)
7yearsago
Reply
NECESSITYisthemotherofinvention...notadversity...
Flag
X
8
incoherent(/member/incoherent)(author) . mikeg103002(/member/mikeg103002)
7yearsago
Yeah,publishingat3AMhasitsdrawbacks!Irealized
thatafterIpostedit,butIjusthaven'tgottenaroundtorewritingit.
Reply
Flag
johnlouis(/member/johnlouis)
7yearsago
Reply
incoherent,
Thanksforthat,Ihavehadalookandseewhatyoumeanaboutthechanneling
/frameconstruction.Ihavebeenthinkingabouttheglassvsbagapproachand
Favorite
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thinkmaybeadoublesidedframewithglassononesideandfilm/thick
transparrentplasticontheotherkindoflikeyoursbuttransparrentplastic
maygivethebestresultsasonesidecanstretchand"vacuumform"tothe
shapeoftheboard.
IwillmeasureupandstartplayingwhenIgetbackfromuniinaweek(last
weekofexams=D)
Regards,
KillerPCBs
Alex byincoherent(/member/incoherent/)
h(/id/KillerPCBs/)
12Steps
Collection
johnlouis(/member/johnlouis)
7yearsago
Flag
IMadeit!
Reply
Hi,thanksforreplying!
Alexisindeedmyrealname,johnlouisthemiddlebits=D
Ihavespentagoodwhilethinkingaboutthisframe,Ineedtodosome.5mm
pitchsurfacemountstuffsoonsowasplanningacompleteUVboxrebuildthe
currentoneisaclassicscannerenclosure(usinglidforpressure)andphilips
solariumlampjob.Iplantouseanatachiecasewitharaisinglid(on
collapsabletelescopicstylestilts)withtheUVlightsinthebottomofthecase,
alongwithvacuumpumpandballistsand(possibly)acollimatorifIcanfigure
outwhatisreallyneededforone.
Aremovabledoublesidedglassvacuumframefordoingdoublesidedwork
nearthelid/storedinthelidbutslidableupanddownthestilts.
Iwasthinkingofgettingtworeallysimplepictureframesandmillingatrough
(moat)aroundtheoutsideoftheglassandthenputtingathinrubberseal
aroundtheoutsideofthetrough,thenthreadingafittingintothetroughfromthe
outside,allowingtheglasssurfacestoalmosttouchwhenvacuumedtogether,
henceworkingkindoflikeaflowerpressonthePCB.Myonlyworriesisthat
theglassmaycrackorthatbecauseneitherofthesurfaceshaveany"give"the
requirespressurewillnothavethedesiredeffect...
FromyourdescriptionIassumetheUsectionchannelisonthetopbit(withthe
plasticsheeting)andthepipetappedintotheUchannel?
Cheers,
Alex
Flag
X
8
incoherent(/member/incoherent)(author) . johnlouis(/member/johnlouis)
7yearsago
Alex,
Reply
Here(http://www.flickr.com/photos/36079246@N03/)aresomepicsofmy
vacuumframe.Incidentally,Iscannedapreregistered,doublesided
transparencywhileworkingonthePCBinstructableandfoundthescan
madeitappeartobeverypoorlyregistered(see4thpicintheseries).I
thinkthiswasduetotheverywideanglenatureofthescanneropticsas
wellasthetheseparationofthelayersdespitethelidbeingclosed.The
effectcouldhavebeencausedbytotalinternalreflectionevenifthelayers
weretightlypressedtogether,butInevertrieditagainwithavacuum
bag/frametodiagnosetheproblem.Thepointisthatthescannerlidmay
notpressaseffectivelyasyoumightthink.Oh,yeah(ADDmomenthere),
youmightbeabletomakeakindofhybridvacuumframe/bagbyplacing
atransparentplasticfilmbetweentheglassandtheframe.
Regards,
incoherent
Flag
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