With the coming of very cheap blue laser diodes, PCB fabrication has become increasingly interesting. Instead of making a photoresist, placing it over a piece of pre-sensitized copper clad board, and putting the whole assemblage under a blacklight, it’s possible to put a photomask on a board with a tiny bit of very blue light. All you need is a CNC machine. A 3D printer can be a very precise CNC machine, and when you combine these two ideas together, you can make printed circuit boards with an Ultimaker.
[Geggo] had the idea of attaching a blue laser diode to his Ultimaker to burn a few traces into presensitized copper board. With a 3D printed adapter, he was able to mount the diode and associated electronics right on the extruder body. With a small ring to tighten up the aperture, [geggo] was able to put a 50 micrometer wide dot of light on a piece of copper. The laser is powered directly from the PWM fan output on the printer controller board, allowing this entire mish-mash of cheap electronics to be controlled via G-code.
A few experiments were necessary to determine the correct speeds and power settings, with the best results being 1000 mm per minute at 40 mA. The finished board looks fantastic, and a few minutes after [geggo] was done etching a board, he started using his 3D printer as a printer. It’s a result that is so good, so easy to accomplish, and requires so little effort it makes us wonder why we don’t see more of this.