Recently I’ve been getting curious about interesting PCB shapes. In the past I’ve always used simple Polygons, perhaps rounding out the corners to make the design a little more aesthetically pleasing. The board to the right was my introduction to the possibilities of oddly shaped boards. It’s designed to couple with a piezo buzzer (used as an actuator). I’ve been planning to have it fabricated out of FPC (Flexible Printed Circuits), but with fabrication being so cheap I sent it to OSHPark to see what they’d make of it. OSHPark doesn’t have hard specs around internal routing, but in my experience they’re up to try anything (and they’re quality is always great). The width of the prongs on the PCB shown is 5mm. I figured it was a risk, and that it was likely the FR4 could break, but it came back great!
This has led me to the realization that my boards could look much more exciting than they do currently, and that our highly optimized modern PCB fabrication process provides a lot of room for experimentation. This article will discuss some of the options available when creating non-traditional PCBs.