DIY Circuit Boards Look Professional

Professional Looking DIY PCB Boards

Making PCBs at home is a great means to get your prototype up and running without having to wait weeks for a professionally made board. Regardless if these prototype boards are milled or etched, they are easily identified as ‘home brew’ due to their ‘unfinished’ appearance. [HomeDIY&Stuff] has put together a little how-to on the process for making DIY PCBs look a little closer to a professionally manufactured board.

The process starts out with designing the board in a PCB program. There are a lot of these programs available. Eagle is a popular choice and has a free version available. Once the layout it finalized, the design is printed out on a transparent sheet of plastic. A blank copper-clad PCB board that already has a UV sensitive coating applied are available for purchase and is what is used in this example. The transparency is placed over the PCB blank and then exposed to UV light. The coating on the PCB cures where ever the UV light passes through the open areas of the transparency.

Once the transparency is removed, there is a noticeable difference in coating color where it has cured. This board is now placed in a developer solution that removes the un-cured UV sensitive coating. A Ferric Chloride acid bath then etches away at the now-exposed copper. The cured coating from the previous step protects the copper at the trace locations during the etch process. The result is a board with copper where you want it and none where you don’t. If the board has any through-hole components, this would be the time to drill those holes.

Up to this point the process has been pretty standard for homemade PCBs and the next part is certainly the most interesting but, unfortunately, is also the worst documented step; the solder mask and silk screening. It appears that two silk screens are produced, one for the solder mask and one for the silk screen. The artwork for making the silk screens can be output from the PCB design software. There is no mention of the solder mask material used but oil-based silk screen ink is specified. Although the details are lacking, the photos show that it works pretty well. If you have had any experience with silk screening DIY PCBs, let us know in the comments.

Exposing PCBs with a home made laser printer

Making your own printed circuit boards – as useful as it is – is a pain. Using the very popular toner transfer method requires a dozen steps that have to go perfectly the first time, and milling boards on a CNC machine creates a lot of mess. The most industrious hackers are able to bodge up a direct-to-board printer from an old inkjet printer, but these builds are usually a little kludgy. [Tixiv]‘s LaserExposer board printer is one of the first builds we’ve seen that does away with all the negatives of the other techniques of PCB manufacturing and turns making your own boards into a very, very simple process.

The LaserExposer uses photosensitive copper board, like many of the other PCB printers we’ve seen. Instead of printing out the board artwork to a transparency or mask, [Tixiv] used a 1 Watt 445nm blue laser with a hexagonal mirror to directly expose the artwork onto the board, line by line.

The entire device is built around an old flatbed scanner that slowly crawls over the PCB, exposing the traces of copper to be etched away. This required reverse engineering the mirror motor control board from an 90s-era laser printer and building a circuit to precisely control the timing of the laser. [Tixiv] eventually got everything working and after etching had some of the most professional looking home-brew boards we’ve ever seen.

[Tixiv] put up a demo video of his build (after the break, German audio, YouTube has captions…). Anyone have an old flatbed scanner lying around?

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