Introduction to PCB Design

(with Eagle)

OMG Assistants (7 Dec 2015) By: Yeo Kheng Meng ([email protected])

OMG Public (21-22 Jan 2016) https://github.com/yeokm1/intro-to-pcb-design-eagle
1
About Me
Graduated from NUS Computer Science in 2015

Engineer at med-tech startup Algo Access

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What is a PCB?
Printed Circuit Board
A printed circuit board (PCB) mechanically supports and electrically
connects electronic components using conductive tracks, pads and other
features etched from copper sheets laminated onto a non-conductive substrate.
Wikipedia

Layman definition:
A board that lets you attach components to make a
circuit.

3
 Before the PCB

vs

Point to point wire wrapping Modern PCB of Novena laptop

Source: https://cdn.sparkfun.com/r/700-700/assets/1/3/b/5/8/50cba0dcce395fb716000000.jpg
Source: http://bunniefoo.com/novena/pvt2_release/novena_pvt2_top_sm.jpg 4
Motivation for makers?
Space and weight constraints
Making multiple copies of a design
Reduce mistakes in manual wiring/soldering
Aesthetics
Durability

5
 Objective of lesson
Fundamental knowledge to
Understand PCB concepts
Design a PCB
Send for manufacturing
Properly share your design with others
Efficient SMD assembling techniques

6
 Structure of a 1-layer PCB board

Modified from: https://cdn.sparkfun.com/assets/3/f/c/b/c/50d0c95bce395fd321000000.png

Usually 1.6mm thick applies to 2-4 layers too

Silkscreen (usually white):
Ink text. Usually used to mark out components
Soldermask (usually green):
Prevent solder (paste) from flowing out of designated areas forming solder bridges
Made of lacquer polymer that is solderphobic
Protects copper layer from oxidation
Copper:
Contains the traces (wires) between components
Also contains a ground/power plane (to be explained later)
Substrate
Gives the PCB mechanical strength and rigidity
Usually made of FR-4, composite of fibreglass and epoxy resin
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Structure of a (2) multi-layer PCB board

Source: http://techdocs.altium.com/display/ADRR/PCB_Obj-Via((Via))_AD

2-layer board = 2 copper layers, 4-layer board = 4 copper layers, etc

2-layer boards good enough for most use-cases
Silkscreen and soldermask on top and bottom only
Vias
Hole in PCB that electrically connects points between copper layers
1. Blind (only for >2 layer board)
2. Buried (only for >2 layer board)
3. Through-hole

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Electronic Design Automation (EDA) Software
Software that helps you design PCBs
Eagle
Commonly used by makers + Adafruit + Sparkfun
Extensive library support
User-interface so-so
Lite version supports max 2 copper layers, 100 x 80 mm board size
Not the best for high-speed designs
Multi-platform
Saved as XML (ASCII) files, great for version-control

Altium Designer
Industry standard
De-facto option for high-speed designs and complex PCBs
Circuit simulation
User-interface is unrivaled IMO
File saved as binary format, terrible for version-control
Windows-only
Expensive: US$10K/license

KiCad
Recently becoming more popular
Free & open-source with no limitations
Libraries not as common
Saves in ASCII files, great for version-control
Multi-platform
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Component packages
2D physical dimension of a component
Determines number of solder pads/sizes
Common surface-mount packages
2-pin passives (dont rely on external power)
0603 (0.063 inch 0.031 inch), 0805 (0.079 in 0.049 in), 1206 (0.126 inch 0.063 inch),
SOD-123 (Small outline diode)
MELF (Metal electrode leadless face) cylindrical SMT component
3 pins Active Components (rely on external power)
SOT23, SOT-223-4 (Small Outline Transistor: 2.2mm pitch, 3 pins front, 4 pins total),
Integrated circuits (ICs), usually dual-inline or square
SOIC-16 (Small Outline Integrated Circuit 16 pins)
SSOP-28 (Shrink small outline package 28 pins)
TQFP-32 (Thin Quad Flat Package 32 pins)
QFN-48 (Quad Flat No leads 48 pins)
Others
Ports like USB, audio,
Board to board connectors like DF40C(2.0)-70DS-0.4V
Pin headers
uFL antenna connector

https://github.com/yeokm1/open-source-pcb-ruler 10
https://github.com/hemalchevli/Open-Source-PCB-Ruler
PCB Design/Manufacturing Workflow
1. Establish project requirements

2. Acquire parts and prototype

3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

7. Do 3D rendering

8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

10. Set PCB fabrication settings

11. Write out bill of materials (BOM)

12. PCB Assembly

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1. Establish project requirements
1. Establish project requirements

2. Acquire parts and prototype

3. Design your PCB schematic

Circuit that blinks an LED 4. Run electrical rule check (ERC).

Customisable blink period 5. Design board: place parts & wiring

Customisable blink cycle 6. Setup/run design rule check (DRC)

Run on CR2032 coin cells 7. Do 3D rendering

Can run off USB power

8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

Power switch
10. Set PCB fabrication settings

11. Write out bill of materials (BOM)

12. PCB Assembly

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 2. Acquire parts and prototype
Consult data sheets to understand part 1. Establish project requirements
selection choices
Logic Components 2. Acquire parts and prototype

Texas Instruments TLC555 timer

Switch (C1 selection) 3. Design your PCB schematic

C1: 33uF/100uF capacitor

R1: 4.7kohm resistor 4. Run electrical rule check (ERC).

R2: 10k potentiometer

2x 0.1uF decouple capacitors 5. Design board: place parts & wiring
Required according to TLC555 data sheet
6. Setup/run design rule check (DRC)
Output components TLC555 cannot source high
5mm 20mA Red LED currents so we use a
transistor to control the LED. 7. Do 3D rendering
100ohm current limiting resistor for LED
ON Semiconductor P2N2222A NPN Transistor
8. Use CAM file to generate Gerbers
1k ohm base resistor

Power components 9. Zip up relevant Gerber files

2x CR2032 battery holders
Micro-USB female connector 10. Set PCB fabrication settings
3.3V low-dropout TC1262 regulator
Diodes for battery protection 11. Write out bill of materials (BOM)
1uF output decouple capacitor
Required according to TC1262 datasheet
12. PCB Assembly
Switch to ON/OFF circuit

*Quantity of 1 unless otherwise stated

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Reference: http://www.circuitbasics.com/555-timer-basics-astable-mode/
 3a. Design your PCB Schematic
Schematic defines connections between components 1. Establish project requirements

2. Acquire parts and prototype

1. Open Eagle and add external libraries

3. Design your PCB schematic
2. Import libraries.
Locate the libraries folder I have provided 4. Run electrical rule check (ERC).

Drag-and-drop the *.lbr files one by one into Eagle 5. Design board: place parts & wiring
Control Panel Libraries folder
Right-Click on Libraries Folder -> Use all 6. Setup/run design rule check (DRC)

7. Do 3D rendering

8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

10. Set PCB fabrication settings

11. Write out bill of materials (BOM)

12. PCB Assembly

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 3b. Design your PCB Schematic
Create and save schematic file (part and connection layout) 1. Establish project requirements

Create a folder on desktop blinker 2. Acquire parts and prototype

Create new schematic *.sch: File -> New -> Schematic

3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

7. Do 3D rendering

Save schematic
8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

10. Set PCB fabrication settings

11. Write out bill of materials (BOM)

12. PCB Assembly

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 3c. Design your PCB Schematic
Add all Power components first
Micro-USB female connector 1. Establish project requirements

Seeed-OPL-Connector -> MICRO-USB-SMD(ZX62-B-5PA)

2. Acquire parts and prototype
Or search 320010005 obtained via Seeedstudio OPL website
http://www.seeedstudio.com/depot/OPLopen-parts-library-catalog-c-
3. Design your PCB schematic
136_138/

3.3V LDO 4. Run electrical rule check (ERC).

bt_regulator -> TC1262 -> SOT-223-3

5. Design board: place parts & wiring
1uF decoupling resistor
rcl- > CPOL-US -> CPOL-USUD-4X5,8 6. Setup/run design rule check (DRC)

2x Diodes
7. Do 3D rendering
Seeed-OPL-Diode -> SMD-DIODE-SCHOTTKY-20V-500MA(SOD-123)
Or search 304020028 8. Use CAM file to generate Gerbers

2x CR2032 battery holders

9. Zip up relevant Gerber files
cr2032-large-side -> CR2032SMT

Through-hole switch 10. Set PCB fabrication settings

Sparkfun-Electromechanical -> SWITCH_SPDT -> SWITCH-SPDTPTH

11. Write out bill of materials (BOM)
VCC and GND wiring net
Just search for them 12. PCB Assembly
There are 2 functionally identical supply1 and supply2 options for VCC and
GND, just pick any one you prefer. 16
 3d. Design your PCB Schematic
Maneuvering and layout
Zoom with scroll-wheel 1. Establish project requirements

Click-drag middle mouse button to move sheet 2. Acquire parts and prototype

Rotate components 3. Design your PCB schematic

Choose Move command
Click component + sign then right-click 4. Run electrical rule check (ERC).

Define component value if needed

5. Design board: place parts & wiring
Right-click component -> Value

Delete object with trash icon 6. Setup/run design rule check (DRC)

Wiring 7. Do 3D rendering

8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

10. Set PCB fabrication settings

Use Net command 11. Write out bill of materials (BOM)

Link components together
Hover mouse just overlapping the contacts 12. PCB Assembly
Press Alt increased precision key if wire cannot overlap
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Left-click to set and also to change direction
 3e. Design your PCB Schematic
Add and wire Logic Components
1. Establish project requirements
Ignore TIMER_OUTPUT
TLC555 timer (dual in-line package) 2. Acquire parts and prototype

st-microelectronics -> NE555 3. Design your PCB schematic

Not exact component but good enough

4.7kohm axial resistor 4. Run electrical rule check (ERC).

resistor -> R-US_ -> R-US_0207/10

5. Design board: place parts & wiring
2mm diameter, 7mm length, 10mm lead length

10kohm potentiometer 6. Setup/run design rule check (DRC)

Sparkfun-Electromechanical -> TRIMPOT -> TRIMPOT-PTH-KNOB

7. Do 3D rendering
Through-hole switch
Sparkfun-Electromechanical -> SWITCH_SPDT -> SWITCH-SPDTPTH 8. Use CAM file to generate Gerbers

33uF and 100uF aluminum electrolytic can capacitors 9. Zip up relevant Gerber files
resistor -> CPOL-US -> CPOL-USE2-5
2mm lead spacing, 5mm diameter, polarised 10. Set PCB fabrication settings

2x 0.1uF ceramic decoupling capacitors 11. Write out bill of materials (BOM)
resistor -> C-US -> C-US025-025X050
2.5mm x 5mm area 12. PCB Assembly

VCC and GND 18

Just search for them
 3f. Design your PCB Schematic
Expected result of Logic circuitry
1. Establish project requirements
Ignore TIMER_OUTPUT for now
2. Acquire parts and prototype

3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

7. Do 3D rendering

8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

10. Set PCB fabrication settings

11. Write out bill of materials (BOM)

12. PCB Assembly

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 3g. Design your PCB Schematic
Add and wire Output Components
1. Establish project requirements
Ignore TIMER_OUTPUT for now
100ohm and 1kohm axial resistor 2. Acquire parts and prototype

resistor -> R-US_ -> R-US_0207/10 3. Design your PCB schematic

2mm diameter, 7mm length, 10mm lead length

5mm Red LED 4. Run electrical rule check (ERC).

led -> LED -> LED5MM

5. Design board: place parts & wiring
ON Semiconductor P2N2222A NPN Transistor (TO92 package)
transistor -> 2N3565 6. Setup/run design rule check (DRC)

Not exact component but good enough

7. Do 3D rendering
VCC and GND
Just search for them 8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

10. Set PCB fabrication settings

11. Write out bill of materials (BOM)

12. PCB Assembly

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 3h. Design your PCB Schematic
Wiring nets
1. Establish project requirements

2. Acquire parts and prototype

3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

Our custom net

6. Setup/run design rule check (DRC)

7. Do 3D rendering
Connects between two regions
VCC and GND are Eagles provided wiring nets 8. Use CAM file to generate Gerbers

We now connect logic circuit to the output circuit via TIMER_OUTPUT

9. Zip up relevant Gerber files
Steps
1. Extend a short dummy wire on one side 10. Set PCB fabrication settings
2. Right click, choose Label
3. Position N$ label just beside wire 11. Write out bill of materials (BOM)
4. Rename to something easier like TIMER_OUTPUT
5. Repeat for the other end 12. PCB Assembly

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 3i. Design your PCB Schematic
(Grounded) Mounting holes
1. Establish project requirements

2. Acquire parts and prototype

3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

Allows your PCB to be secured to external case
Grounded by screws. 7. Do 3D rendering

Can also use normal ungrounded mounting holes 8. Use CAM file to generate Gerbers

Appears in schematic as it is an electrical connection

9. Zip up relevant Gerber files
Mounting hole
Grounded: 10. Set PCB fabrication settings
holes -> MOUNT-PAD-ROUND -> MOUNT-PAD-ROUND3.2
Ungrounded: 11. Write out bill of materials (BOM)

holes -> MOUNT-HOLE -> MOUNT-HOLE3.2

3.2mm hole fits M3 screws with slight allowance 12. PCB Assembly

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 4. Run electrical check (ERC)
Tests if your wiring has been done properly
1. Establish project requirements
Not foolproof but usually good enough to detect weird or
missing connections 2. Acquire parts and prototype

Run ERC regularly, assign to shortcut key. Options -> Assign 3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

7. Do 3D rendering

8. Use CAM file to generate Gerbers

Correct ALL errors
9. Zip up relevant Gerber files
Inspect all warnings
Correct if needed 10. Set PCB fabrication settings
Ignore if you are sure
I discourage approving 11. Write out bill of materials (BOM)

12. PCB Assembly

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 5a. Design board: place parts & wiring
Create and save board file (board layout)
1. Establish project requirements
File -> Switch to board
Initial board configuration 2. Acquire parts and prototype

1. Adjust grid settings to mm as shown.

3. Design your PCB schematic
View -> Grid

4. Run electrical rule check (ERC).

2. Create keyboard shortcuts for commonly
used functions.
5. Design board: place parts & wiring
Options -> Assign
Not case-sensitive
6. Setup/run design rule check (DRC)
End with ;
3. Enable Vector font 7. Do 3D rendering
1. Options -> User Interface
2. Tick Always vector font
8. Use CAM file to generate Gerbers
3. Tick Persistent

9. Zip up relevant Gerber files

CAM Processor can
only convert vector
fonts into Gerbers 10. Set PCB fabrication settings

properly.
11. Write out bill of materials (BOM)
See:
http://www.cadsoft 12. PCB Assembly
usa.com/training-
service/faq/#c95 24
 6a. Setup/run design rule check (DRC)
Design rules provided by fabricator to check if your PCB adheres to requirements
1. Establish project requirements
Download PCB fabricator DRU, in this case Elecrow
http://www.elecrow.com/10pcs-2-layer-pcb-p-1175.html 2. Acquire parts and prototype

http://www.elecrow.com/download/Elecrow_PCB_eagle_rule.zip
3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

7. Do 3D rendering

8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

10. Set PCB fabrication settings

11. Write out bill of materials (BOM)

12. PCB Assembly

25
*I use Elecrow as a learning example here but it does not mean I endorse this company in any way.
 6b. Setup/run design rule check (DRC)
Load DRU file just once
1. Establish project requirements
Press check to check your board or use keyboard shortcut
2. Acquire parts and prototype

3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

7. Do 3D rendering
Rectify all errors
8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

10. Set PCB fabrication settings

11. Write out bill of materials (BOM)

12. PCB Assembly

26
 5b. Design board: place parts & wiring
General board steps
1. Adjust board size to your requirements eg: 99mm x 49mm (check
1. Establish project requirements
fabricator price point)

2. Acquire parts and prototype

3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

7. Do 3D rendering

2. Place ground/power plane on Top layer using polygon function. 1mm away 8. Use CAM file to generate Gerbers
from edges to ease future resizing. Set polygon name.
9. Zip up relevant Gerber files

10. Set PCB fabrication settings

11. Write out bill of materials (BOM)

12. PCB Assembly

27
 5c. Design board: place parts & wiring
General board steps
3. Component placement order
1. Establish project requirements
1. Place mounting holes
2. User-facing components, like USB connectors, switches and LEDs
2. Acquire parts and prototype
3. Large components
4. Everything else
3. Design your PCB schematic
4. Wiring order (Trace width usually the size of the solder pads)
1. Wire high-speed connections, avoid using vias
4. Run electrical rule check (ERC).
2. Wire power connections with wider traces
3. Wire everything else
5. Design board: place parts & wiring
5. Execute DRC check and rectify if needed
6. Silkscreen placement order (dont overlap with any holes/vias/parts) 6. Setup/run design rule check (DRC)
1. Smash component & adjust part designators if required to minimise confusion
2. Add descriptive text to certain areas to silkscreen 7. Do 3D rendering
3. Add PCB description/revision
7. Miter corners 8. Use CAM file to generate Gerbers
8. Make sure Ratsnest gives Nothing to do
9. Zip up relevant Gerber files
Tips
Execute Ratsnest to recalculate remaining airwires position as much as 10. Set PCB fabrication settings
possible after every operation
Run DRC after you make every change to catch problems earlier 11. Write out bill of materials (BOM)
Wire at 45 degree angles to reduce signal reflection
12. PCB Assembly

28
 7. Do 3D rendering
Use this website http://3dbrdviewer.cytec.bg/
1. Establish project requirements

2. Acquire parts and prototype

3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

7. Do 3D rendering

8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

Check for any visible errors, especially silkscreen overlap

10. Set PCB fabrication settings
Check for components closeness.
Go back to Step 5 if not satisfied 11. Write out bill of materials (BOM)

12. PCB Assembly

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 8. Use CAM file to generate Gerbers
Gerber files
2D vector format used by PCB fabricator to make PCBs for you 1. Establish project requirements

CAM file provided by fabricator to help you generate Gerber layer files 2. Acquire parts and prototype

Download PCB fabricators CAM processor, in this case Elecrow

3. Design your PCB schematic
http://www.elecrow.com/10pcs-2-layer-pcb-p-1175.html
http://www.elecrow.com/download/Elecrow_Gerber_Generater_Drill 4. Run electrical rule check (ERC).

Align.zip
5. Design board: place parts & wiring
Use the correct CAM file according to number of layers like 2 layers
Open CAM Processor: File -> CAM Processor 6. Setup/run design rule check (DRC)

Once in CAM Processor, load the CAM job as shown below 7. Do 3D rendering

8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

10. Set PCB fabrication settings

11. Write out bill of materials (BOM)

12. PCB Assembly

Once you are done, click Process Job 30

 9. Zip up relevant Gerber files
See what files are required by the PCB fabricator
1. Establish project requirements
Elecrows requirements:
2. Acquire parts and prototype

3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

7. Do 3D rendering

Go to saved folder and zip up the required files 8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

Rightfully you should inspect your Gerber files for potential mistakes
using software/websites like: 10. Set PCB fabrication settings

GR-Prevue: http://www.graphicode.com/GC-Prevue_Gerber_Viewer
http://circuitpeople.com/ 11. Write out bill of materials (BOM)

http://mayhewlabs.com/webGerber/
But so far I dont have any problems so I usually skip the Gerber file check step 12. PCB Assembly

31
 10a. Set PCB fabrication settings
Go to order page http://www.elecrow.com/10pcs-2-layer-pcb-p-1175.html
1. Establish project requirements

2. Acquire parts and prototype

3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

7. Do 3D rendering

8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

10. Set PCB fabrication settings

11. Write out bill of materials (BOM)

12. PCB Assembly

Basic options like PCB size, color and lead time self explanatory
32
 10b. Set PCB fabrication settings
1. Establish project requirements

2. Acquire parts and prototype

3. Design your PCB schematic

4. Run electrical rule check (ERC).

Layer
1-layer with mask both side: 1 copper layer only but you want both sides soldermask/silkscreen
5. Design board: place parts & wiring
1-layer with mask one side: 1 copper layer only and you want one side soldermask/silkscreen
2-layer: normal two copper layer boards
6. Setup/run design rule check (DRC)
Copper weight:
Copper layer thickness and amount, 1oz is usually enough
7. Do 3D rendering
PCB Thickness:
Typical is 1.6mm 8. Use CAM file to generate Gerbers
Elecrow can go as thin as 0.6mm for normal FR4 PCBs. Flex PCBs can go even thinner like 0.1mm
9. Zip up relevant Gerber files
Surface finish
HASL vs ENIG next slide
10. Set PCB fabrication settings
PCB Stencil
Help you solder SMT components if you have solder paste and reflow oven/hotplate 11. Write out bill of materials (BOM)
Frame or no frame provided. I normally go with the frame as it just costs slightly more.

Panelizing 12. PCB Assembly

Squeeze many small PCBs into one piece to save space but you have to cut after receiving.
I normally pick Single PCB with milling as I have no need to panelize my PCB 33
 10c. Set PCB fabrication settings
1. Establish project requirements

2. Acquire parts and prototype

3. Design your PCB schematic

4. Run electrical rule check (ERC).

HASL vs ENIG 5. Design board: place parts & wiring

HASL (lead-free) ENIG
6. Setup/run design rule check (DRC)
Acronym for Hot Air Solder Levelling Electroless nickel immersion gold

How it is made? Copper surfaces covered Copper surfaces covered with 7. Do 3D rendering
with solder by dipping PCB nickel with gold coating via
in solder then blowing away immersion 8. Use CAM file to generate Gerbers
Coating evenness Uneven, dont use for fine- Very even coat, must use if you
pitch SMD components have fine SMD components. 9. Zip up relevant Gerber files
Durability Reasonable, but dont Better than HASL, can last for
expose too long to air months 10. Set PCB fabrication settings
Solderability Great So-so
(should not factor in your decision)
11. Write out bill of materials (BOM)
Cost Low High
12. PCB Assembly
Others:
Electrolytic Gold-plating, Immersion Silver, Immersion Tin, Organic Surface Protectant 34
 11. Write out bill of materials (BOM)
Export BOM and modify.
So others can replicate your PCB 1. Establish project requirements

Go to Schematic view, File -> Export -> BOM

2. Acquire parts and prototype
Select Parts type and CSV format as shown
3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

7. Do 3D rendering

Use Libreoffice to open CSV file and save in its native ODS format
8. Use CAM file to generate Gerbers
CSV not enough features, does not store column width
Some Excel versions have difficulty opening CSV file generated by Eagle
9. Zip up relevant Gerber files
Open-source format

Modifying the generated BOM 10. Set PCB fabrication settings

1. Remove mounting holes
2. Collapse duplicate devices and combine their part designators 11. Write out bill of materials (BOM)
3. Remove: Description, OC_FARNELL, OC_NEWARK, PROD_ID, last VALUE column
4. Add: Quantity, Unit Cost , Total Unit cost (=Quantity * Unit Cost), Source webpage 12. PCB Assembly
5. Modify the generic Eagle BOM with the actual BOM data (also add PCB Fab cost)
6. Can have final Total Cost at bottom if you wish 35
 12a. PCB Assembly
Manual Soldering
Soldering station
1. Establish project requirements
Through-hole and SMT components
2. Acquire parts and prototype

Specialised SMD Soldering techniques (with stencil and paste)

3. Design your PCB schematic
Hot air blower
4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

Hot plate
7. Do 3D rendering

8. Use CAM file to generate Gerbers

9. Zip up relevant Gerber files

10. Set PCB fabrication settings

Reflow oven
11. Write out bill of materials (BOM)

12. PCB Assembly

36
 12b. PCB Assembly
Reflow Soldering only for surface-mount components
Requires stencil and solder paste 1. Establish project requirements

FIRST stencil/reflow the SMD components THEN solder the through-hole

components by hand. 2. Acquire parts and prototype

3. Design your PCB schematic

4. Run electrical rule check (ERC).

5. Design board: place parts & wiring

6. Setup/run design rule check (DRC)

7. Do 3D rendering

A typical thermal profile, consult data sheet to determine optimum profile

8. Use CAM file to generate Gerbers
Thermal profile based on:
Lead vs lead-free solder paste
9. Zip up relevant Gerber files
Lead vs lead-free components
Lead vs lead-free use depends on RoHS compliance
10. Set PCB fabrication settings
Profile Steps
1. Preheat: Flux activation 11. Write out bill of materials (BOM)
2. Soak: Ensure all board and components are at the same temperature
3. Reflow: Melts solder paste and let it settle properly on the solder pads 12. PCB Assembly
4. Cooling: Brings temperature back down at controlled rate to prevent thermal stress
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Source: http://www.compuphase.com/electronics/reflowsolderprofiles.htm
 DIY PCB Fabrication (Toner transfer)
Materials
Liquid Mixture: Vineger, Table Salt, Hydrogen Peroxide (H202)
Transfer paper
FR-4 board
Steps
1. Print circuit diagram on transfer paper using laser printer
2. Iron/Heat press transfer paper into FR-4 board
https://www.youtube.com/watch?v=dvLRrXjktbE
3. Mix liquid mixture of vinegar, H202 and salt
4. Submerge FR-4 board in liquid mixture and agitate
5. Continue until all exposed copper has been eaten away. (Toner covers areas you want to leave behind)

6. Use a solvent/paint thinner to wipe off the toner

Source, Leon Lim:

http://gylim78.blogspot.sg/2014/07/the-diy-pcb-making-guide.html
http://gylim78.blogspot.sg/2015/05/pcb-board-gallery.html

Export DIY PCB images from Eagle:

7. Drill holes to create vias http://yeokhengmeng.com/2016/03/eagle-file-to-diy-pcb-etching/ 38
Time to design your own board!

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Final Words
This is just the beginning
Practice makes perfect, the more PCBs you
design/fabricate, the better you will get

Unlikely to get right on the first fabrication attempt

2-3 times or more per design

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