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Ultimate Guide to PC Board Thickness

Ultimate Guide to PC Board Thickness

PC Board, PCB Design, PCB Fabrication, Printed Circuit Board, printed circuit board assembly, Printed Circuit board Fabrication, , , , ,

Printed circuit boards are vital parts of electronic technology and you have to focus on various factors to design or buy them. PCB thickness is the most important factor in this case. However, the weight, profile, and components of PCB also matter a lot.
PCB thickness can influence its function, affecting resistance and conductivity. The application of a circuit board determines its thickness and there are different levels of thickness in this regard.

A-Thickness Of A Standard PCB

A standard printed circuit board has different types, like one-sided having one layer of copper or double-sided boar with two layers of copper. Whereas multiple layers are also in practice. The double-sided PCB has a substrate layer between two layers.
Generally, a standard circuit board is 1.57mm or 0.0065 inches as it used to be the thickness of the plywood in old circuit boards. Later, multilayered PCBs emerged and the designer had to make their thickness according to the connectors. So, the designers need a standard thickness of 1.57mm.
The board thickness also ranges from 0.008 inches to 0.240 inches, and you can select any thickness between these figures to match the PCB application. You can give your requirements to the manufacturer or can hire an engineer to evaluate PCB thickness for a specific application.

Copper Thickness Of A Standard PCB

You also have to consider the copper thickness as it helps get the desired PC Board thickness and influences its function. Like, one square foot area of the circuit board needs an ounce of copper which becomes 1.37 mils. But, it can vary, depending on your needs according to the current that passes through the board.
Most circuits come up with 1oz copper i.e. equal to one ounce. However, it can be 2oz if the circuit board needs high currents. Designers often increase the track’s thickness which results in higher current points. Moreover, they don’t add anti-welding masks because they want to reinforce the track during assembly, like with tin.
Sometimes laminate manufacturers use an intermediate thickness of copper just to lower the price, like 0.75 oz. But, such a practice is technically not so good. Experts don’t recommend this because the PCB thickness also reduces during mechanical or chemical cleaning. The popular copper thickness is 0.5oz, like in the case of two-sided laminates.

Trace Thickness In PCB

You have to specify the trace thickness while making the Gerber files to avoid overheating. Trace thickness is the trace width that can tolerate the temperature difference ranging from the standard to maximum operating temperatures. In other words, the trace width should be enough to bear increased temperatures. Besides, PCB width calculators are available to find the trace width.

 

Ultimate Guide to PC Board Thickness
Thickness guide of PC Board

B-FR4 Thickness Of A Standard PCB

FR4 is the flame retardant material which is a fiberglass sheet with epoxy lamination. FR4 shows the quality of the laminate in PCB. Generally, it’s the base material for Printed Circuit board Fabrication.
The rigidity occurs due to epoxy that resists fire, and engineers prefer it for its low cost. The dielectric strength of FR4 is high, moreover, it is lightweight and also resists heat and water. So, they are compatible with different environments.
The FR4 thickness lies between 3 and 10 inches, and it can cause an increase in PCB thickness. You have to evaluate the FR4 thickness by considering the board components and space.
Design Parameters of an FR4 Board Thickness
Generally, the designers prefer thick boards because thin FR4 boards get damaged faster, especially when they are large, besides, the grooves are missing. Whereas thicker boards provide more flexibility and also include grooves.
Should Be Flexible
Thin circuit boards are more flexible than heavy or thick boards, especially in the medical field’s control unit. But, thinner circuit boards cause lots of issues during soldering that results in bending. Eventually, several other components also get curved, damaging a board’s connections.
Compatible Impedance
PCB thickness is crucial while constructing multilayer boards became you have to match the impedance. Besides, you also have to consider each layer’s capacitance. The board won’t function if its impedance is not compatible.
Edge Connectors
The edge connectors also directly influence the PCB thickness, especially when there is FR4. An incompatible mating part of the connectors can result in PCB damage. So, you must be clear about materials before PCB manufacturing.
PCB Weight
More thickness means more weight and increased shipping costs. So, you have to keep in mind the weight of the circuit board that determines the weight of the final product. Experts find thinner layers better than the others, however, one should go for a standard PCB thickness.
C- Core Thickness of Standard PCB
The core is a PCB layer having FR4 between copper layers or foils. The core of a standard PCB involves certain items of which copper should be precise. It’s a fiber mesh layer having resin, moreover, it has incurred FR4 as well.
The core thickness of the standard PCB becomes hard to select during a multilayer PCB design. However, sometimes PCB remains effective even if the core thickness is not compatible. But, the end product should perform high for which PCB should have accurate thickness. The designer must consider this factor and share the right details with the manufacturer.
The weight of the core thickness goes from 1 to 3 ounces depending on the requirements. The weight also includes copper layers that can be on both sides. However, if both sides’ weight differs, it would cause additional expenses and poor results. The core thickness with the desired copper weight is also possible through pre-preg sheets.
D-Two-Layered PCB Thickness
Printed circuit boards with multiple layers are getting popular these days. They include glass fabric based on epoxy having copper coils. A multi-layered PCB can bear high loads, however, its thickness remains only 63mm.
Complex PCBs need wiring, resulting in more layers, so PCB thickness becomes up to 93mm. The thickness of a standard PCB also gets influenced by foil lamination, if the lamination consists of 4 layers, 0.031 would be the PCB thickness. The thickness would become 0.062 if the foil lamination includes 6 layers.
Likewise, the thickness becomes 0.062 to 0.125 for 8 to 10-layer PCB. Your requirements can also demand half, one, or two-ounce copper foil.
PCB Thickness Allowance
Also known as PCB thickness allowance, it is the tolerance for PCB manufacturing substances. It can be more or less than the average amount of material. Designers consider certain parameters for it, such as the IPC guidelines. Such design parameters help manufacturers have the flexibility to develop a circuit board that performs well.

FAQs

What Is The Importance Of Knowing PCB Thickness?
You have to focus on the circuit board thickness because both electronic devices and boards have a tendency to shrink. So the board has to be thin and lightweight to help manufacturers place it into the device. The weight of the final product also matters as thicker circuit boards can increase the weight of the device, resulting in increased shipping costs.
How Many Layers Are There In A Standard PCB fabrication?
There are various types of standard printed circuit boards, including one-sided having one layer of copper or double-sided board with two layers of copper. There is also PCB with more than two layers called a multi-layered PCB.
What Is FR4 In A Standard PCB?
FR4 is the flame retardant material which is a fiberglass sheet with epoxy lamination. FR4 shows the quality of the laminate in PCB. Generally, it’s the base material of a rigid circuit board.
What Is Core Thickness In A Standard PCB?
PCB layer with FR4 between copper layers or foils is known as the core. The core of a standard PCB consists of various elements, including copper that has to be accurate. PCB core is a fiber mesh layer having resin, moreover, it has incurred FR4 as well.
What To Consider While Designing A Standard PCB?
Designers have to focus on various factors to design or buy a printed circuit board. PCB thickness is the most important factor, but the weight, profile, and components of PCB also matter a lot.
What is Trace Thickness In PCB?
Trace thickness is the trace width that can tolerate the temperature difference ranging from the standard to maximum operating temperatures. You have to specify the trace thickness while making the Gerber files to avoid overheating.

Wrap Up

Now, you know how important it is to consider PCB thickness in different ways. PCB thickness can influence its function, affecting resistance and conductivity. The application of a circuit board determines its thickness and there are different levels of thickness in this regard. You can have a good circuit board by choosing the board thickness wisely, depending on its application.
Would like to know more about printed circuit board assembly? Email us at sales@pnconline.com

PCB Design for Beginners

PCB Design for Beginners

PC Board, PCB Design, Printed Circuit Board, printed circuit board assembly, SMT assembly, , , ,

Whether you’re just starting in the world of electronics or you’ve been doing it for years, there’s always something new to learn. Design, while it can seem complex at first, really boils down to some simple rules and techniques that will help you to save time and money while making your projects run more smoothly.
There are plenty of steps and processes involved in the PC design process, and as such, there are many things that you need to know in order to create an effective Design. This guide will help you understand how to go about the process of designing your PCBs and take you from beginner to expert.

What Is A Printed Circuit Board (PCB)?

A PCB, is a self-contained module of interconnected electronic components found in devices ranging from common beepers, pagers, and radios to sophisticated radar and computer systems. The circuits are formed by a thin layer of conducting material deposited, or printed, on the surface of an insulating board known as the substrate.
Layers of insulation called traces carry electrical currents between various points on the board. Capacitors, resistors, inductors, semiconductors such as transistors and diodes, and connectors may also be attached to this surface through holes that have been punched into it with a special machine called a drill press. All parts on the board must have features small enough so that they can fit inside this drilled hole with no problems at all.
One major aspect of a design is to make sure there is plenty of room around each component to minimize noise caused by electromagnetic interference. In addition, great care should be taken not to put two closely spaced components on top of one another because this could lead to one component interfering with the other’s signal voltage.

What Are The Parts Of A PCB?

A PCB is made up of a few different parts, such as the board, the surface finish, the solder mask, and the silkscreen. The board is the green part that everything is attached to.
The surface finish is the layer that helps protect the copper from corrosion. The solder mask is the green coating that helps prevent short circuits.

The silkscreen is the white print on the board that has the logo and part numbers. There are many more parts that go into a PC Board but these are the basics.

The materials used in building a PCB will vary depending on how they will be used. There are four main types of boards, including paper-backed FR4, epoxy-coated FR4, Kapton, and ceramic substrates.

Paper-backed boards are usually cheaper because they don’t require special equipment to make them whereas other boards may need expensive machinery or specialized chemicals during production.

Epoxy-coated boards can be damaged by water and UV light while Kapton doesn’t corrode as FR4 boards do. Ceramic boards can also get damaged easily.

Paper-backed FR4 is often used in low-volume production environments with surface mount technology (SMT) devices such as resistors, capacitors, diodes, integrated circuits, and inductors.

How Do I Begin?

Maybe you’ve designed a few simple circuits by hand and are ready to take the next step. Or maybe you’ve never designed a circuit before but have some experience with computer-aided design (CAD) software. Either way, this guide will teach you the basics of PCB design.
The first thing you’ll need is an electronic CAD program. The most popular programs are Eagle, KiCad, and Altium Designer. They each offer trial versions that let you get started without investing any money upfront. You can download them from their websites or find them on your operating system’s app store.

Choosing the Right Software

When it comes to PCB design software, there are a few different programs you can choose from. But which one is the best for you? It depends on your needs and what you’re looking for in a program. If you’re just starting, we recommend trying out a few different programs to see which one you’re most comfortable with.

Once you have a better idea of what you need, then you can start narrowing down your options. A good example of this would be if you needed to design circuits with specific electrical requirements or desired material properties. You should also see if you work with a team of people on projects and want them all using the same system. The biggest thing when choosing a PCB design software is making sure that it meets your needs as well as your budget.

If you want to learn how to design your PCBs, you’ll need to know how to use a CAD program. These design programs are used by designers to create electronic schematics and layout boards. The schematic consists of all the components needed in order to power the circuit while the layout shows where each component should be placed on the board. Two popular CAD platforms include EagleCAD and KiCad. Both are open source but have different strengths.

EagleCAD is known for its intuitive interface while KiCad has better compatibility with older hardware. One important thing to note is that every time you make changes to the schematic or layout, they need to be re-synced with one another. If they aren’t then small mistakes can easily turn into large ones later on. To avoid this problem, check the sync settings at the top of the screen before making any modifications.

PCB Design for Beginners
PCB Design for Beginners

Learning About Board Etching And Printing

Before you can start creating your PCBs, it’s important to understand the basics of board etching and printing. Board etching is the process of creating electrical circuits on a substrate, usually using a photochemical process. This is typically done by first creating a master template, which is then used to create a negative film. The negative film is then used to create a resist-coated board, which is exposed to UV light and developed. The exposed areas are then etched away, leaving behind the desired circuit pattern.
In contrast, PCB printing is often performed in what’s called surface mount technology, SMT. In this type of manufacturing, components are placed onto a flat surface, like sometimes copper coated with solder paste applied between them to connect them.
A final coating may be applied before the SMT assembly undergoes reflow soldering. Once finished, the boards can be separated from one another and packaged. There are many different types of PCBs including single-sided boards, double-sided boards, flex boards, and rigid-flex boards that may also be utilized.
Choosing the right kind of board depends largely on how they will be used as well as cost factors such as materials and labor requirements. For example, flex boards are less expensive than rigid-flex boards because they use flexible plastics rather than stiffer fiberglass or FR4 substrates.
However, the tradeoff is that these boards cannot be mounted to something. Single-sided boards are also cheaper but may not offer the same level of protection against EMI interference as other types of PCBs might be able to provide.
Double-sided boards, on the other hand, offer more protection against interference but require more work when designing them due to routing limitations. They also take up more space than single-sided boards, meaning fewer components can fit on each board.
When deciding on the appropriate PCB type for your project, it’s important to weigh all of these considerations carefully so that you make an informed decision about what is best for your needs.

Tips for Successful Board Prototyping

1. Use quality materials- This is important because you want your prototype to look and feel like the final product. Plus, it will help ensure that your board functions correctly.

2. Make sure your design is clear and concise- A well-designed board will be easier to troubleshoot and will save you time and money in the long run.

3. Pay attention to details – This includes things like trace widths, spacing, and clearance. The smallest of details can have a big impact on the success of your PCB.

4. Create a schematic – If you’re not experienced with schematics, there are plenty of resources online to help guide you through it. Remember that your schematic should match up with what’s on the PCB and vice versa! For example, if you plan to use LEDs on your board then make sure they’re included in the schematic.

You’ll also need to decide which type of LED, transparent or non-transparent you want so you can include that information as well. Keep these four tips in mind when designing your next PCB and get ready for a successful prototyping experience.

5. Build a prototype from scratch – We know that building your first PCB from scratch can be intimidating, but there are quite a few options out there for those interested in learning how to build their boards. So far, this guide would be enough for those who are new to PCBs.
Would like to know more about Design or printed circuit board assembly? Email us at sales@pnconline.com

Aluminum Backed Printed Circuit Board Fabrication

Aluminum Backed PCB Fabrication in PCB Assembly

PC Board, PCB Design, Printed Circuit Board, printed circuit board assembly, , ,

PCB is a power supply source to run different electronic devices. In PCB Assembly, Printed circuit boards have different base materials, depending on their application. In general, circuit boards have a fiberglass base, but aluminum-backed PCB is also common it has a metal base but the laminate is covered with copper. Such PCB performs better due to high-end thermal conductivity and electrical insulation.
The aluminum-backed circuit board involves alloy plates which are a blend of three metals, including aluminum, silicon, and magnesium. These PCBs are different from fiberglass. Let’s discuss different layers in an aluminum PCB.
First Layer or Base: It has an aluminum alloy that helps have an effective through-hole PCB.
Thermal Insulation: It consists of ceramic polymer and it is vital for a PCB. The polymer has a high thermal resistance, good viscoelastic properties, and a high resistance to mechanical stresses.
Copper Foil: It is the circuit layer with copper foil, and it may weigh up to one to 10 ounces.
Dielectric Layer: the purpose of the dielectric is to absorb heat when there is current in the circuits. Then it goes to aluminum, dispersing the heat. PCB having a better thermal resistance enhances its life.

Manufacturing of Aluminum PCB

The construction of aluminum Printed Circuit Board involves different layers as described here. The base and circuit layers have a thin dielectric layer between them. After that comes the etching of copper foil, or circuit layer to help you have a certain pattern. All these layers eliminate a circuit’s heat.

Types of Aluminum PCB

The aluminum circuit board has three main types, such as through-hole, flexible, and hybrid. Let’s discuss them one by one.
Through-Hole Aluminum Circuit Board: the pre-drilling is involved in a through-hole circuit board. The hole is then filled with the dielectric.
Flexible Aluminum Circuit Board: such a circuit board has a flexible dielectric to provide high flexibility, electrical insulation, and thermal conductivity. Aluminum and dielectric make a product flexible having different shapes. Moreover, it involves low-cost fixtures and connectors.
Hybrid Aluminum Circuit Board: a hybrid aluminum circuit board is common in RF applications. Its thermal performance is very high if you use it in a product with a standard FR4.

Aluminum Backed Printed Circuit Board Fabrication
Aluminum Backed Printed Circuit Board Fabrication

Benefits of Aluminum Circuit Boards

You can take benefit from an aluminum PCB in manage ways, such as

  • It is not costly because aluminum is easily available in many areas, and its mining is not hard like other metals. Whereas PCB manufacturing with aluminum also involves less cost, so you can replace heat sinks with aluminum.
  • It is environmental-friendly because it does not emit toxic chemicals. Besides, it is easy to recycle. From construction to its application, an aluminum circuit board is safe for the environment.
  • It does not let the heat damage PCB by keeping the heat away from delicate components.
  • You will find aluminum PCBs stronger than fiberglass and ceramic-based circuit boards. It prevents accidental damage that happens during manufacturing and daily applications.
  • It is also lightweight which reduces the weight of the end product. Such a quality makes it more reliable because it is easy to manage.
  • PC Board having aluminum involves a black or white solder mask.

Applications of Aluminum-Backed PCBs

  • The aluminum-backed PCB is suitable for devices that need more heat tolerance and dissipation. They are highly effective in preventing the PCB components from heat and help manage temperatures while designing a PCB. In this sense, the aluminum-backed PCB is 10 times more effective than a fiberglass PCB.
  • When the thermal dissipation is high, it helps design high-density and high-power circuit boards.
  • Circuit boards with aluminum bases are useful for LED applications, such as automotive lights, traffic lights, and ordinary lighting.
  • Aluminum-backed circuit boards enhance the density of the LEDs and also help the installed LEDs to function at more power, maintaining temperatures.
  • Printed circuit boards with an aluminum base help in having fewer safety margins with power LEDs as compared to the traditional PCB design. When the operating temperature is low, the LEDs can have a longer lifespan.
  • Aluminum-based PCB is also useful for power supplies, motor controllers, automotive applications, and circuitry with high currents.
  • Such boards have a simple design due to high heat dissipation. It prevents heat sinking and forced air, eventually reducing the expenses of the design.
  • Make sure to store your aluminum PCB in a dark and dry place. Avoid placing them in a damp room as it can change their color to yellow or black due to moisture absorption.
  • You will often see aluminum circuit boards in power converting devices and LED. It enhances the LED’s lifespan, making it stable. Aluminum substrates are used in street lights or other residential or commercial lights.
  • Aluminum circuit boards help power converters to manage electronic devices and charge currents. It is also useful for several other industries.
  • Aluminum PCB ensures less damage to the circuit board by keeping heat away from vital components. Moreover, it comes up with high thermal conductivity.
  • It can tolerate high temperatures and manage high-density PCBs. Moreover, it is less vulnerable to damage due to more durability. It is not toxic to the environment.
  • A non-metal PCB lacks thermal conductivity and you have to design it with a conductive material. You need heat sinks, forced air, and copped vias to prevent the circuit from heat.

Which Conductive Material Will Be The Best For My Application?
Several factors determine the kind of circuit board you require. Generally, aluminum PCB is ideal where high-heat dissipation is required. The properties of aluminum are compatible with high-power and thick designs, which is not the case with standard circuit boards.
However, designers having a low budget can use non-metal substrates, such as flex circuits having polymer. It can tolerate vibrations better than aluminum-flex substrates.
Standard or Traditional Printed Circuit Boards
The dielectric and copper make standard circuit boards having different layers. Most standard PCBs have FR4 substrate, moreover, fiberglass is less costly. The board has many layers of copper and other elements, such as silkscreen and solder masks help in conductivity and component placement.
The layers are either on both sides or one side of the circuit board. Whereas there are also stack-ups with several layers. Standard circuit boards can power both high-end and low-end electronic devices. Single-sided boards are used in less complex products, such as calculators. But, multilayer PCBs are essential for complex devices like supercomputers or space equipment.
Pros and Cons of Standard Circuit Boards

    • Generally, the standard PCBs are more adaptable than others. You can use any substrate depending on your budget and durability. You can go for a fiberglass circuit board if your budget is low or if you need a low-intensity board.
    • It is not compatible with high stress, so special applications need flex or radio frequency substrates.
    • On the other hand, FR4 PCBs need additional features to tolerate high heat or temperature.

The application and the kind of device determine if you need a standard circuit board or an aluminum board. You can get the design through online sources or can hire an engineering company for this purpose. You can also read our other posts to understand a common PCB.

FAQs

What is an Aluminum PCB?
The main structure of an aluminum PCB is just like other PCBs having silkscreen, solder mask, and copper. It has an aluminum substrate, but it can also be a mix of aluminum and fiberglass.

Why Should I Have Aluminum PCB?
Aluminum-backed circuit boards are long-term and durable because they can manage high temperatures and reduce failures. They are also mechanically balanced and the thermal expansion level is also lower compared to other materials.
Where Can I Use Aluminum PCB?
You can use it for multiple lights, such as surgical lighting, interior lighting, landscape lighting, tail light tools, operation theater lighting, etc. Moreover, it is compatible with power converters, auto dashboards, powerful scanners signal beacons, and power transmissions.
What Is A Hybrid Aluminum PCB?
A hybrid aluminum circuit board is common in RF applications. Its thermal performance is very high if you use it in a product with a standard FR4.
What Is The Dielectric Layer In PCB?
The purpose of the dielectric is to absorb heat when there is current in the circuits. After that, it goes to aluminum to disperse the heat. PCB having a better thermal resistance enhances its life.
What is Flexible Aluminum PCB?
The flexible aluminum circuit board has a flexible dielectric to provide high flexibility, electrical insulation, and thermal conductivity. Aluminum and dielectric make a product flexible having different shapes. Moreover, it involves low-cost fixtures and connectors.

Conclusion

Aluminum boards are more niche-oriented than other circuit boards. However, their cost is higher than standard PCBs. You can take benefit from aluminum PCB if your application involves high temperatures, or it won’t be a good investment. The aluminum circuit board has three main types, such as through-hole, flexible, and hybrid. Your requirements determine the kind of PCB you should have.
Would like to know more about Aluminum Backed PCB or printed circuit board assembly? Email us at sales@pnconline.com

Four Stages of PCB Design and Assembling

Four Stages of PCB Design and Assembling

PC Board, pcb assembly, pcb assembly services, Printed Circuit Board, SMT assembly, , , ,

PCB is a printed circuit board that helps connect different electrical components. The board is a combination of laminated material, and the copper foil laid on a non-conductive substrate.
A PCB is the main part of any electronic device, so it has to be perfect. It should have functional components and microelectronics circuits to perform well. Development of PCB goes through different processes that you should know well. PCB manufacturing has 4 stages, including design, manufacturing, PCB assembly, and PCB testing.

First Stage- Design

PCB design involves different steps, such as schematic design, layout planning, the placement of the components, routing, and manufacturing files.
PCB schematic design: It is a blueprint of PC design that shows all PCB components with symbols. The schematic design is always according to the technical requirements of the user.
Layout planning: After the schematic design, you have to develop the layout of a PCB that includes physical components’ models,the shape of the PCB, and the structure of a PCB.
Placement of components: It involves planning the placement of various components. You decide on the PCB layers according to your requirements. The right placement of the components ensures a flawless board, decreasing the production cost.
First of all, the designer places the fixed components in the layout, including switches and connectors.
Then, the critical components are placed, such as memory chips, microprocessors, as well as power supplies.
Then the supporting components of the PCB are placed, like inductors, capacitors, and resistors.
In the end, the decoupling capacitors and terminating resistors are placed.
Routing: Once the components are placed, you have to connect all components through trace routing. There are four ways to do so, such as manual routing, auto-interactive routing, semi-automatic, and batch-auto routing. You can choose any method according to your Printed Circuit Board and budget.
Design: In this stage, you have to plan for the number of board layers, dimension of the board, and types of components. You can use a special app in this case, such as EDA or electronic design automation. The designer often adopts the SMT instead of a through-hole technology, depending on your requirements.Once the design is over, you can export the design files to CAD or Gerber format.
Preparation of manufacturing files: This is the last stage of design where the designer exports the Gerber files for manufacturing. The manufacturer needs these files to develop a printed circuit board.

Four Stages of PCB Design and Assembling
Four Stages of PCB Design and Assembling

Stage 2-Manufacturing of Circuit Board

Once the manufacturer receives all design drawings, he starts making PCB. It involves different stages as described below:
Design Imaging:The manufacturer uses a plotter to convert the PCB design files into filmslike they resemble the photo negatives of the schematic design. The printer uses black and clear inks for inner and outer layers. Copper traces and circuits are shown with black ink, whereas the non-conductive parts are shown with clearink.
Printing of Inner Layers On Copper: It is the initial stage of PCB manufacturing. The engineer uses a substrate material to make a laminated board. Like, epoxy resin or fiberglass are common in this case. The design of the PCB is printed on the board, and then he pre-bondscopper on a board’s both sides. After that comes the etching of copper, and then the board is protected through a photo-sensitive film.
UltravioletLight: the manufacturer then exposes the resist-covered PCB to UV light to strengthen the photo-reactive material. Then the board is cleaned with an alkaline solution to get rid of unnecessary copper particles. The expert checks the board to remove any errors and then goes to the next stage. The main aim of UV blasting is to develop a PCB Board according to the schematic drawing.
Inner layer’s etching: copper’s inner layer needs chemical etching for removal. The process of photoresist prevents the essential copper from etching. The board size determines the amount of the solution and etching time which is less for small boards but more for large boards.
Some other manufacturing processes include:

  • Alignment of layers
  • Optical testing
  • Layer pressing and lamination
  • Drilling
  • Plating of PCB
  • Imaging of external layer
  • Etching of external layer
  • Solder mask
  • Silk screening
  • PCB finishing
  • Testing
  • Profiling
  • Quality testing
  • Packaging of PCB
  • Shipping of PCB

Stage 3-PCB Assembly

The assembly of a PCB involves four stages, such as soldering, placement of components, solder pasting, and testing. Let’s review them in detail.
Solder Pasting: It is like t-shirt screening, as it involves solder paste stenciling. The stencil is made of stainless steel and it’s very thin. You have to use the stencil to apply the paste in areas where different components will be installed. In this process, flux is used for melting the paste to help it bond to the PCB.
Placementofthe Components: Once you are done with the solder paste, you need a pick and place the tool for the components. Generally, it is SMT or surface mount technology where components are placed on the PCB surface. Initially, it used to be a manual process and assemblers used tweezers to pick and place different components on the board. However, new technology has made this process automated due to robotics and it’s more precise and consistent.
Soldering of PCB: After the placement of components, you have to place the PCB on a conveyor belt to help a board move to a reflow oven that heats the board. The heating helps melt the solder paste, and bond the components on the board permanently. However, if the board has more components other than SMDs, it would need a through-hole insertion that involves more advanced soldering.
Testing of PCB Quality: Sometimes, the components are misplaced during reflow when the PCB is moving. This issue may cause a poor connection, or no connection at all, or the parts are not well-connected. So, you need to inspect the PCB to ensure a flawless function. A PCB can fail this test even if it passed other tests, and a failed PCB goes to scrap or you have to recycle it with all essential processes until you get a flawless circuit board.

Stage4-PCB Testing

Manufacturers use different methods for PCB testing to ensure that it will function correctly. These methods include in-circuit, optical inspection, flying probe, turn-in, x-ray, anda functional test.
In-Circuit: It is also known as ICT, or you can call it the bed-of-nails inspection. In this method, PCB is pressed on the bed of probes. It is highly accurate because it checks all components of a PCB. You can also test the BGAs with this method. Moreover, it also tests the solder integrity of the bottom-terminated components.
However, this test is expensive and time-consuming. Moreover, it does not test the non-electrical parts and connectors.
AOI, Automated Optical Inspection: This testing method involves a visual inspection of the board. It is done with the help of HD cameras, LED lights, UV, and high-level infrared. The test is contact-free and helps check poor solder joints or missing parts. It also tests the smt assembly issues and it’s very accurate.
However, it only inspects the preprogrammed errors and can’t check defects regarding glue or sealing.
Flying Probe Test: It involves probes that help test the upper and lower surface of a PCB. This PCB testing method is cost-effective, consumes less time, is easy to do, and is compatible with many applications of PCB assembly. However, it is slower than other testing methods and not ideal for complex testing.
Burn-In Test: In this test, PCB is exposed to a high temperature to see if it works well. It ensures a lifetime product and enhances the brand because of an effective end product.
However, this test is costly and can affect a PCB by damaging its components. Moreover, it can be less reliable due to voltage scaling.
Inspecting Through X-Ray: It involves an x-ray machine that inspects a PCB. It thoroughly checks soldering which is hard to detect with AOI. The x-ray inspection is ideal for thick or multilayered PCBs. It also detects the voids or bubbles and can also check the components under a shield.
However, it needs expensive x-ray machinesand can cause hazards in the workplace.
Functional Test of PCB: It involves functional testers that you connect to the edge connector. It creates an electronic environment for which a PCB is made. It inspects the functional errors and identifies the analog issues. It also checks issues with digital circuitry.
However, it is very costly and needs high-end tools, which are too expensive. It needs a proper understanding of the working atmosphere of the DUT.

Final Thoughts

The development of a PCB involves different processes, including design, printing, assembling, and testing. Each stage is further divided into different parts, and you have to understand all stages to create a flawless PCB.
The board is a combination of laminated material, and the copper foil laid on a non-conductive substrate. A PCB is the main part of any electronic device, so it has to be perfect.
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Microwave Printed Circuit Board Concept

Microwave Printed Circuit BoardConcept

circuit board assembly, Circuit board fabrication, PC Board, PCB manufacturer, , ,

A microwave circuit refers to any electrical or electronic device which operates on microwaves or uses microwaves for its operation. Some examples include radar systems, satellite dishes, cell phone towers, and TV antennas among others. Such circuits are designed to operate at specific frequencies or bandwidths so that they do not interfere with each other.
A microwave is an electromagnetic wave of frequency between 1GHz and 30GHz. It falls under the band B, C, D, and E in IEEE standards. Microwaves occupy a large part of the entire RF spectrum as compared to other frequencies. The global demand for communication devices such as routers, DSL, and mobile phones has increased significantly due to technological advancements such as internet connectivity being provided by these devices and advancements in technology by small-sized electronic components that can operate at high frequencies. As a result, there is an increase in demand for microwave circuit design services.
Microwave PCBs have to meet certain requirements that have not changed even though the designs have.

Understanding The Concept

So, what is microwave PCB? Simply put, it’s a pc board that incorporates circuitry optimized for frequency bands in which microwave signals are most commonly used. As the boards are designed specifically for such frequencies, they offer superior performance over traditional boards in terms of both design and reliability. Besides, their smaller size and lower overall weight make them perfect for use in applications where space and transportation costs are at a premium.

Microwave Printed Circuit Board Concept
Microwave Printed Circuit Board Concept

Why Microwave Technology?

The microwave portion of telecommunications is used for point-to-point voice and data communications. You can also use it for two-way radio, cable television, and telegraphy in a limited range of frequencies. As it allows information transmission at high speeds over long distances, it is very common in military organizations. For these reasons and more, microwave technology plays an essential role in today’s technological world.

As such, it was important that an efficient way to transmit microwaves be developed, the result was a device called a microstrip line. In short, when combined with other components, microstrip lines are what allow microwaves to travel great distances while maintaining optimal signal strength.

A microstrip line consists of three main parts, including a metal foil, dielectric material, and a ground plane. Metal foil serves as an antenna, and the dielectric material acts as a waveguide. Whereas the ground plane provides electrical shielding. These three elements are placed on top of one another and bonded together using heat or pressure, which creates a single unit known as a structure.

What Are The Factors That We Need To Consider While Selecting The Right Board?

Choosing a board for microwave design is not an easy task. There are several factors that we need to consider such as frequency, applications, and modes of use. There are three main types of boards, including through-hole, single-sided, and multi-layer boards. It is also very important that you pick out a board that matches your frequency range.
For example, you need a board with wider spacing between conducting tracks at higher frequencies than low frequencies. So, make sure that you select the right one depending on your frequency range.
The next thing that you need to look into is your application or project needs. Depending upon your requirement, you can go ahead with either through-hole or SMD-style component placement methods.
The final step in choosing a microwave PCB will be deciding on the thickness of the copper traces before the Circuit board fabrication process. You will have to choose according to your project needs whether thin or thick copper traces would be best suited for your application. But, keep in mind that thicker copper traces provide better current carrying capacity but they are more expensive than thinner ones. So, again it all depends on what kind of budget you have set aside for your project.
Every board has its unique features, so do check out every detail before buying one. A well-known feature of these boards is their ability to withstand high temperatures without getting damaged. This makes them ideal for high-temperature environments like ovens, motors, etc.
Another advantage of using these boards is their small size which makes them easy to handle and transport from one place to another. They also come with different pin configurations like double row, single row, and even no pin configuration options. Some of them also offer the ground plane on both sides which helps in reducing noise levels due to capacitive coupling.
In addition to all these advantages, most of these boards are made up of epoxy glass material that provides insulation against electric fields and other environmental factors.

Installation of Components onto A Microwave PCB

Let’s now take a quick look at how we can install our components onto a microwave PCB. First of all, get yourself ready by wearing safety glasses and gloves so that you don’t end up hurting yourself during installation. Make sure that you have gathered all the tools required for installation beforehand.
Next, remove any existing solder mask and protective coating from the surface of your board. Make sure that there is no dirt or dust present on it as well. If necessary clean it thoroughly with acetone and then wipe dry with a lint-free cloth or paper towel.
After doing so you can proceed to install the components onto it just like any other circuit board out there. Remember to always start with your smallest components first and work your way up to larger ones. Before soldering it is recommended that you apply a thin coat of flux on all surfaces where you are going to be placing your components. Then apply a little bit of solder paste on each pad and lastly place your component in position and heat it with a soldering iron.
Make sure that you inspect for proper alignment of your parts and if needed apply extra flux or reposition it until everything looks just right. Once you are satisfied with your results, it’s time to apply a generous amount of solder over all your components. Once you have done so, wait for it to cool down and that’s it.

How Do I Choose My Microwave PCB Manufacturer?

Before you start shopping for a company to make your circuit boards, there are a few things you should know. Here’s a quick rundown of some key questions you should ask yourself as you’re shopping around, such as:
• Does your board require special materials?
• Do you need services outside of just PCB manufacturing?
• How many layers do you need?
• What sort of electrical isolation is needed between high-voltage and low-voltage areas on your board?
• How much space will you need for mounting components?
Once you have answers to these questions, it will be easier to find a vendor that can meet all of your needs. Of course, in order to get accurate information from vendors about their capabilities, you may need to provide them with more details about your project than what we’ve provided here. They must understand exactly what kind of design you’re working with so they can give you honest feedback about whether or not they’re able to work with it.

What Is Hybrid Microwave Circuit

A hybrid microwave involves a thin film or thick film technology to construct different microwave circuits using a medium that can transmit signals. The medium, in this case, is mostly sapphire, alumina porcelain, ceramics of high level, or quartz.
There are two types of hybrid microwave circuits, passive and active. Passive hybrid circuits consist of passive elements like resistors, capacitors, inductors, and filters. Whereas active hybrid circuits use active devices like transistors, diodes, etc.
Active hybrid circuits have better performance than passive ones, but their fabrication process is more complex than passive ones because they contain semiconductor elements, unlike passive elements. Thus it is easier to fabricate passive hybrid circuits than active ones.
There are various factors affecting the microwave circuit design such as size, power consumption, cost of materials used, and the operating temperature. These factors must be considered while designing a microwave circuit.
Understanding the Lumped Componentization of a Microwave Circuit
A lumped component model is one of several techniques used to analyze and design high-frequency microwave circuits. It was originally developed for analysis and design in communication systems. It is characterized by using lumped elements (e.g., resistors, capacitors, inductors) instead of transmission lines or other forms of circuit elements whose behavior is dominated by distributed parameters like permittivity and permeability.
In addition to being useful for analysis, lumped element models are also useful for conceptual designs because they make it easier to visualize components and their interconnections. The concept of lumped element models is very similar to that of ideal transformers used in a single-sideband modulation. In this model, an ideal transformer represents an actual transformer with losses and non-ideal characteristics asleakage reactanceare replaced by zero values.
The equivalent circuit consists of an impedance connected between port 1 and the ground, plus a series capacitor representing the leakage reactance and shunt conductance. This technique is often referred to as lumped parameter modeling. Other examples include bridge networks used in an RF filter design and the current source inverters used in active filters.
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