PCBs Straight From The Magazine

June 19, 2026 by Bryan Cockfield 1 Comment

It’s never been easier to get a printed circuit board made. In fact, almost every electronics video out on the internet will incessantly remind you of this fact now. But making a custom PCB wasn’t always as straightforward as sending a KiCad file to a board house. Many DIY methods involve harsh chemicals and tedious processes, but did have the potential benefit of taking much less time than waiting on boards to arrive in the mail. [Bettina Neumryr] is demonstrating one of these older methods, called the toner transfer method, using a circuit that was printed directly in an old magazine.

The first part of the toner transfer method is to create an image that can be printed. Since this circuit came from a magazine, it is first scanned in to a computer and imported into GIMP, where it can be scaled to match the size of the components and then sharpened to make a crisp print. With the image ready, it’s time to print the image onto some toner transfer paper, ensuring that the printer in question is a laser printer which actually uses toner. From there, a sheet of blank copper PCB is prepared and then the toner is transferred by heating, in this case using a laminator. After that its etched, removing all of the copper not protected by the toner, and then the toner itself can be removed which leaves behind the copper traces.

For those of you who were around when toner transfer was in vogue, this video might not have much value. But for anyone who can’t use a board manufacturer for whatever reason or is looking for alternatives, a modern video showing the method could be much more useful and have better context for beginners than videos made a decade or more ago now. Some of those older methods include similar processes using inkjet printers instead, but there are more modern DIY methods as well using lasers or CNC machines too.

Continue reading “PCBs Straight From The Magazine” →

DIY Ceramic Circuit Boards Surely Count As Solarpunk

June 3, 2026 by Tyler August 17 Comments

Solarpunk is all about combining that DIY hacker ethos with sustainability and renewable resources. Our usual PCB manufacturing methods, with their bevy of chemical baths and petrochemical resins aren’t exactly the most sustainable. Digging up some clay and firing it into a circuit board? Very sustainable! And apparently doable, as demonstrated by [Emily Velasco] on Mastadon.

Of course anybody could take a ceramic wafer and call it a circuit board, but that’s only part of what [Emily] did. The ceramic wafer is apparently native clay, which is very cool. Even cooler is that she’s baked the traces into the pottery. While you could conceivably use some sort of conductive glaze for this, what [Emily] did was stamp her desired circuit into the unfired ceramic using a 3D-printed stamp, and then fill the depression with copper powder after the first firing. After that, a second firing is done in a reducing atmosphere to melt/sinter the copper together–it’s not totally clear which is happening here–without burning up.

The results speak for themselves; on the finished demo board, a pair of LEDs blink happily away, driven by the astable oscillator circuit baked right into the clay– and of course the components soldered to it. You’ll have to click through to see it, though.

Given those not-so-sustainable petrochemicals behind our favourite PCBs may be in short supply, this is a timely hack. If it seems familiar, that’s because we featured virtually the same technique last year, but using more-expensive silver powder instead of copper, and a campfire instead of a kiln.

Thanks to [smellsofbikes] for the tip!

Through-Glass Vias And The Long Road To Glass Substrates

May 25, 2026 by Maya Posch 16 Comments

Glass-based substrates are slowly beginning to push out organic substrates – as also commonly used in PCBs – due to often superior material properties for packaging. One area where glass substrates have however struggled is with through-hole vias and providing the conductive copper path through them. A 2024 article by [Keith Best] gives a good overview of the topic, with recent news showing how much companies like Intel are pushing for glass substrates, specifically for the packaging of dies.

One major advantage with vias in glass substrates is that they can be much smaller, enabling smaller than 0.1 mm diameter holes with far finer pitch. The challenge here is to make perfect holes with a laser that are defect-free, as well as have the intended diameter.

After that this through-glass via (TGV) has to be coated or filled with copper, much like their organic equivalent. Said TGV can be fully filled with copper, or use plating and add dielectric filler. Detecting flaws in such a finished TGV is important.

In a 2025 review article of glass substrate technologies by [Pratik Nimbalkar] et al. published in Chips the state of the art at the time was covered. The need for ever higher-density integration options with ASICs is highlight here, especially now that many chips today consist of multiple interconnected dies inside a single package.

The complications of creating TGVs with femtosecond laser pulses in Borofloat 33 glass are highlighted by [Daniel Franz] et al. in a 2025 research article, with microcracks and backside ablation observed without proper precautions, something which previously was often resolved by an etching step following said laser drilling. The main issue here is the post-drilling residual stress from the thermal shock, which the authors demonstrate can be largely prevented with careful tweaking of the laser drilling parameters.

As pointed out in a 2024 review article by [Chen Yu] et al. glass substrates are useful for far more than just high-density chip packaging. Glass substrates are also chemically resistant, have a higher heat resistance, are largely transparent to RF and can be hermetically sealed against outside influences. This makes them great for various advanced sensors and communication devices.

Meanwhile, if you wanted to do some metal-depositing on glass at home, we covered this recently.

A desk fan with an air filter. On the side, the final assembled PCB is visible.

Making A PCB The Old-Fashioned Way

May 21, 2026 by Julian Scheffers 59 Comments

Nearly all modern PCBs are designed with the help of EDA software, but not all of them. [ALTco] shows us the process of plotting out a board the old-fashioned way — by hand.

Back in the day, drawing out the traces on a PCB lead to beautiful, smooth lines that [ALTco] wanted to imitate. But first, he needed to figure out how the rest of the fabrication process worked. He starts by just experimenting, both with the “resist” markers and paint, and the etching compound. Things rarely work first-try, and neither did his home-made etchant. So then it was time to buy some ferric chloride, the standard copper etchant for PBCs. A few more tests sorted out which permanent marker worked best.

[ALTco] starts by thoroughly cleaning a raw copper-clad board so the marker sticks properly, then draws the circuit for a little analog fan controller. The board is then laid in a bath of the etchant for several minutes while gently rocking it to keep the reaction going. Finally the board is taken out, etchant stored for re-use, and the board washed with water and then presumably IPA to remove the remaining marker. Some assembly of the newly-printed circuit board later and you have a cute little smoke absorber for your soldering projects.

Continue reading “Making A PCB The Old-Fashioned Way” →

Two printed circuit boards made from 3D prints and copper foil. One white and one black substrate.

Using 3D Printers To Make Circuit Boards

May 19, 2026 by Julian Scheffers 60 Comments

Custom printed circuit boards have become more and more accessible to the average hobbyist over the last decade. But one problem still remains: your circuits will take at least a couple days to make. But what if you needed some really rapid prototypes? [The Raccoon Lab] shows us how to do it with a 3D printer.

You start with the usual hobby PCB pipeline: take your idea, make a schematic, and then lay it out in KiCad. That’s where the changes start: to keep traces strong, they are made very thick. The PCB is then exported and opened in 3D CAD software, where the traces are extruded to be 2 mm tall. Off to the printer! The newly printed “circuit board” is made conductive by applying copper tape to it, and traces are cut out along their raised edges.

The result is a very quick and dirty PCB. Sure, it isn’t exactly production-ready, but for just about any simple microcontroller project it’ll do just fine, and it’s a whole lot more accessible than milling one using a CNC! We’ve seen a few variations on this approach recently, including some custom software designed to help along the process.
Continue reading “Using 3D Printers To Make Circuit Boards” →

Another Gift To The World From CERN: Their Entire Set Of KiCad Libraries

May 12, 2026 by Jenny List 69 Comments

As the foremost boffins of Europe toil deep underneath the border between Switzerland and France in their never-ending quest to truly understand the fabric of the Universe, they rely on a vast amount of electronics. The PCB layout team at the particle accelerator thus work with a huge array of parts, for which of course they create KiCad libraries. Now the folks at CERN have made those libraries available as open source, so you can benefit from their work.

The libraries themselves can be found in a GitLab repository, and at the moment are offered only for KiCad version 9.x. We tried installing it in our KiCad 10.0 installation and it refused — complaining of a missing JSON file — but we’re assuming that with more time and effort we could have made it happen. We’re told official 10.x compatibility is on the way.

Browsing the repository shows what a multiplicity of parts are included, so we can see this becoming a standard install for many people and the CERN footprints turning up in many projects featured here.

Thanks [Daniel] for the tip!

You’ve Seen The Chip Shortage And The Memory Shortage, Now Prepare For The PCB Shortage

May 6, 2026 by Jenny List 45 Comments

It’s nice to hide away in our little corner of the internet and talk tech, safely away from the turmoil of world events. Sometimes though, geopolitics intrude even into our space, and Reuters are here reporting on a new concern that will probably affect many Hackaday readers. Conflict in the Gulf of Arabia, and in particular raids on Saudi petrochemical plants, is threatening PCB production far away in China.

Most of us probably have a mental image of tankers sailing through the Strait of Hormuz laden with Gulf crude, off to be processed by refineries somewhere else in the world. Certainly a load of oil takes just that route, but for the Saudis and other oil-producing nations in the region, it also makes economic sense to site petrochemical industries at source. They export the much more valuable refined products, among which is the polymer resin used in PCB production. The Reuters report says that consequent to this and a rise in copper prices, the cost of a PCB in China has risen by 40%. Naturally this doesn’t sound like good news.

Here at Hackaday, when it comes to component shortages this isn’t our first rodeo. We’re in the middle of a memory shortage due to AI companies, and the COVID-era chip shortage is still fresh in our minds. Unfortunately, this type of thing as been a regular of the technology world for decades. Here we are with another one, and should we be worried? In the short term it’s certainly a concern as the Gulf conflict is still searching for an end to its uneasy stalemate, but remembering previous shortages we think that global industry will adapt and expand other sources where necessary. Just as with the similar IC encapsulation resin shortage back in the ’90s, it may eventually be the panic more than the shortage which becomes responsible for the price hikes.

We’ve taken an abstract look at global electronic supply chains before.

Header image: Gabriela P., CC BY 4.0.