PCB Design & Fabrication

Chapter-1

PCB Designing Software Introduction

● Schematic Design: Familiarization of the Schematic Editor, Schematic creation, Annotation,

Netlist generation.
● Layout Design: Familiarization of Footprint Editor, Mapping of components, Creation of PCB
layout Schematic.
● Create new schematic components.
● Create new component footprints.

A printed circuit board, also known as a printed wiring board, is found inside an electronic device.
This green board made from precious metals connects all the device’s electrical components and allows it
to function correctly. Without PCBs, electronic devices cannot work.
Schematic Design:

A PCB schematic is a simple two-dimensional circuit design showing the functionality and
connectivity between different components. PCB designs, on the other hand, are three-dimensional layouts
that indicate those components’ locations once you know your circuit works.

The PCB schematic, then, is the first part of designing a printed circuit board. It’s a pictorial
representation, either written or on a computer, that utilizes agreed-upon symbols to describe circuit
connections. It also indicates the components that will be used and how they are connected. Anyone should
be able to pick up and read the PCB schematic.

Its name aptly describes it: the PCB schematic is a plan, a blueprint. Its concern is not where
specifically the components will be located. Instead, the schematic lays out how the PCB will ultimately
achieve connectivity and forms a critical part of the planning process.
Once the blueprint has been completed, the PCB design comes next. The design is the layout, or physical
representation of the PCB schematic and includes the copper track and hole layout. The PCB design does
show the locations of the components mentioned above, as well as their connections with copper.

PCB design is the phase that’s concerned with performance. Engineers build the real components on
top of the PCB design, allowing them to test whether the device works or not. We mentioned before that
anyone should be able to understand a PCB schematic, but the functionality is not readily understood by
looking at the prototype.

Once both of these phases have been completed and you’re satisfied with the performance of your PCB,
printed board circuit manufacturers can help you bring your device to life. Now that you have a broad
overview of the differences between the two, let’s take a closer look at the elements of PCB schematics. As
we mentioned, all the connections are visible, but there are some things to keep in mind:

* To be able to see the connections clearly, they are not created to scale; on the PCB design, they may
be quite close to one another

* Some connections might cross one another, which can’t happen on the physical version
 * Some connections might be on opposing sides of the layout with markings indicating that they are
linked

* This PCB “blueprint” may be represented on one page, two pages, or even several pages–as many as
it takes to fully depict everything that needs to be included in the design

One final thing to note is that more complicated schematics may be grouped by function to aid readability.
Arranging connections in this manner is something that doesn’t happen in the next stage, and schematics
often don’t match up to the final design on the 3-D model.

LayoutDesign:

Now it’s time to take a more in-depth look at PCB designs elements. At this stage, we move from written
blueprints to a physical representation that is constructed using laminate or ceramic material. Some more
complicated applications require the use of flexible PCB when exceptionally tight space is a concern.

The elements of PCB designs follow the blueprint that the schematics process has laid out, but, as we’ve
mentioned, look very distinct visually. We’ve already talked about what the PCB schematics look like, but
what differences can we observe in the design?
 When we talk about PCB designs, we’re talking about a 3-D model that includes the printed circuit board
and the design files. They can be single or multiple layers, though they are most commonly two layers. We
can observe several differences between PCB schematics and PCB design:

* All components will be the right size and in the correct position

* If two connections shouldn’t be connected, they must avoid crossing one another on the same level
either by taking a detour or changing to another PCB layer Additionally, as we touched on briefly, the PCB
design is more concerned with performance, as this is somewhat of a testing phase for the final product. At this point,
the practicalities of how the design must actually work come into play, and the physical requirements of a printed
circuit board must take them into consideration. Some of these things include:

* How components are spaced to allow for adequate heat distribution

* Having connectors on the edges

* How thick the various traces must be with regard to current and heat concerns

Because physical constraints and requirements mean that the PCB design generally looks quite different than what is
mapped on the schematics, the design includes a silkscreen layer.

.
PCB Design Introduction

PCB (Printed Circuit Board) design is a crucial aspect of electronic product development. It involves creating a physical board that
supports and connects various electronic components to form a functional circuit. PCBs provide a reliable and compact platform for
interconnecting components, reducing the complexity of wiring and facilitating the manufacturing process.

Here is a brief introduction to PCB designing:

1.Purpose of PCBs:
- PCBs serve as a foundation for electronic circuits, providing a platform for mounting and interconnecting various electronic
components such as resistors, capacitors, integrated circuits, and connectors.
- They help in reducing the complexity of wiring, making the circuit more compact, organized, and reliable.
- PCBs are used in a wide range of electronic devices, from simple household appliances to complex industrial machinery and
sophisticated electronic gadgets.

2. PCB Components:

- Substrate: The base material of the PCB, usually made of fiberglass-reinforced epoxy laminate. The substrate provides mechanical
support and insulation.

-Copper Layers: Thin layers of copper foil bonded to the substrate. Copper is used for creating conductive traces that connect the
electronic components.

- Solder Mask: A protective layer that covers the copper traces, except where components are soldered. It prevents accidental short
circuits and corrosion.

- Silkscreen: A layer containing markings such as component designators, labels, and other information to aid in assembly and
troubleshooting.

3. PCB Design Process:

- Schematic Design: Create a schematic diagram of the circuit using a software tool. This diagram represents the logical connections
between components.

-Component Placement: Position the components on the board to optimize signal integrity, thermal performance, and ease of
manufacturing.

- Routing: Create the conductive paths (traces) on the PCB that connect the components according to the schematic. Consideration is
given to signal integrity, power distribution, and electromagnetic interference (EMI) during this phase.

- Design Verification: Perform design rule checks (DRC) and other simulations to ensure the PCB meets electrical and manufacturing
requirements.

-Gerber Files Generation: Generate the files needed for manufacturing, including Gerber files, which describe the PCB layout.

4.PCB Design Software:

- Various software tools are available for PCB design, such as Altium Designer, Eagle, KiCad, and OrCAD. These tools provide
features for schematic capture, component placement, routing, and design verification.

5.Considerations in PCB Design:

-Signal Integrity: Ensuring that signals propagate correctly without distortion or interference.
- Power Distribution: Proper distribution of power and ground planes to minimize voltage drops and noise.

-Thermal Management: Efficient dissipation of heat generated by components.

- Manufacturability: Designing the PCB in a way that is cost-effective and easy to manufacture.

6.Advanced PCB Technologies:

- Multilayer PCBs: Utilizing multiple layers of substrate and copper for complex and dense circuit designs.

- High-Frequency PCBs: Designed to handle signals in the radiofrequency (RF) range, common in wireless communication devices.

PCB designing is a multidisciplinary field that requires knowledge in electronics, physics, and engineering, as well as
proficiency in PCB design tools and manufacturing processes. It plays a crucial role in the development of modern electronic
devices by providing a reliable and compact means of interconnecting electronic components.
 PCB FABRICATION

The PCB fabrication process involves several steps to transform a design from a schematic
diagram into a physical circuit board. Here is an overview of the typical PCB fabrication
process:

1. Design Input:
- The process begins with the design input, which includes the electronic schematic and
layout created using PCB design software. Design files, often in Gerber format, are
generated to provide the necessary information for fabrication.

2. Material Selection :
- The base material of the PCB, known as the substrate or core, is selected. Common
materials include fiberglass-reinforced epoxy laminate (FR-4), which is widely used due to
its electrical insulation properties and mechanical strength.

3. Panelization:
- Multiple PCBs are often fabricated on a single large panel to optimize production
efficiency. Panelization involves arranging the individual PCB designs on a larger panel,
allowing multiple boards to be processed simultaneously.

4. Film Generation:
- The Gerber files are used to create photo films for each layer of the PCB. These films
act as masks during the etching process. Each film corresponds to a specific layer, such as
the top copper layer, bottom copper layer, solder mask, and silkscreen.

5. Inner Layer Processing:

- For multilayer PCBs, inner layers are prepared first. A thin copper layer is applied to
both sides of the substrate. The photo films are aligned and exposed to ultraviolet (UV)
light, creating a pattern on the copper layer. This pattern represents the traces and features
of the inner layers.

- After exposure, the board is developed to remove the unexposed photoresist, leaving
behind the desired copper pattern. The board then undergoes an etching process to remove
the excess copper, leaving only the copper traces and features on the inner layers.

- Once the inner layers are processed, they are cleaned and prepared for lamination.
6. Lamination:
- For multilayer PCBs, the inner layers are combined with prepreg layers (layers of
uncured fiberglass and resin) and then pressed together under heat and pressure. This
process bonds the layers into a single, solid board.

7. Drilling:
- Holes are drilled into the board for component leads and vias. The locations of these
holes are specified in the design files. Automated drilling machines are commonly used for
precision and efficiency.

8. Outer Layer Processing:

- The outer layers of the PCB undergo a similar process to the inner layers. Photo films
are used to create patterns on the top and bottom copper layers, and these patterns are
etched to define the traces and features.

9. Solder Mask Application:

- A solder mask is applied to the entire board, leaving openings for component pads and
vias. The solder mask protects the copper traces from environmental factors and prevents
unintended solder bridges during assembly.

10. Silkscreen Printing:

- The silkscreen layer, which contains markings such as component labels and reference
designators, is applied to the PCB using a printing process. This layer is usually white and
provides important information for assembly and troubleshooting.

11.Surface Finish:
- The surface finish is applied to protect the exposed copper surfaces and ensure
solderability. Common surface finishes include HASL (Hot Air Solder Leveling), ENIG
(Electroless Nickel Immersion Gold), and OSP (Organic Solderability Preservatives).

12.Testing:
- Various tests are performed to ensure the quality and functionality of the fabricated
PCB. This may include electrical testing, where the continuity and integrity of traces are
verified, as well as visual inspection for any defects.

13.Routing and Separation:

- After fabrication and testing, the panel is routed to separate the individual PCBs.
Automated routers or milling machines are used to cut along the predefined borders.
14. Quality Control:
- The final step involves rigorous quality control checks to ensure that the fabricated
PCBs meet the specified design requirements and industry standards.

The completed PCBs are then ready for component assembly, where electronic
components are soldered onto the board to create the final electronic product.
 Chapter -2
Tools Used in PCB DESIGNING
 CHAPTER-3

Create new component footprints

1. Create the pads

2. Define component height and area
3. Add silk screen information
4. Save the footprint

Step 1: Create the Pads

You will need the landing pattern for your part, which can be found towards the end of the
component datasheet or in your chosen database library.

Step 2: Define Component Height and Area

In this step, we need to define the height and area occupied by the component. We also need to define the
component type. To access this information, select your new component footprint from the Footprints
list, and click the Edit button. From here, you’ll be able to enter these three pieces of information.

Step 3: Add Silk Screen Information

For this step, we add the silk screen layer image and pin 1 marking. We will follow the suggestion from the
data sheet and indicate only where the corners should be. To make a corner, we create a 0.08 mm line
which you get by selecting the line icon on the PCB Lib Placement toolbar, duplicate it (by copy and paste)
and link them.

Step 4: Save the Footprint

The final step is to create your component is to name and save it so you can add it to your component,
which also includes the schematic symbol. Tip: You will want to make the name unique and searchable so
you can easily locate it.
 CHAPTER-4

Practically PCB Designing

Project-1

Aim: Regulator circuit using 7805

Required Components:
1. AC Voltage Source
2. Transformer-Step down
3. Bridge Rectifier
4. Voltage Regulator-7805
5. Capacitor-1000uf
6. Resistor-1k

Software:
1. Proteus ISIS :-Used for schematic diagrams designing
2. Proteus ARES :-Used for PCB layouts
Fig:-Regulator using 7805 circuit PCB LAYOUT
Theory:

A regulated power supply is very much essential for several electronic devices due to the semiconductor
material employed in them have a fixed rate of current as well as voltage. The device may get damaged if
there is any deviation from the fixed rate. The AC power supply gets converted into constant DC by this
circuit. By the help of a voltage regulator DC, unregulated output will be fixed to a constant voltage. The
circuit is made up of linear voltage regulator 7805 along with capacitors and resistors with bridge rectifier
made up from diodes. From giving an unchanging voltage supply to building confident that output reaches
uninterrupted to the appliance, the diodes along with capacitors handle elevated efficient signal conveyal.

As we have previously talked about that regulated power supply is a device that mechanized on DC
voltages and also it can uphold its output accurately at a fixed voltage all the time although if there is a
significant alteration in the DC input voltage. ICs regulator is mainly used in the circuit to maintain the exact
voltage which is followed by the power supply. A regulator is mainly employed with the capacitor connected
in parallel to the input terminal and the output terminal of the IC regulator. For the checking of gigantic
alterations in the input as well as in the output filter, capacitors are used. While the bypass capacitors are used
to check the small period spikes on the input and output level. Bypass capacitors are mainly of small values
that are used to bypass the small period pulses straight into the Earth.
Procedure:
1.Connect the circuit as for the circuit diagram.
2.Connect the supply to the power supply circuit.
3.Apply the value.
4. Check the OUTPUT.
 Project-2

Aim:Full-wave Rectifier

Required Components:
1.AC Voltage source
2.Resistor-10k
3.Capacitor-10uf
4.Bridge Rectifier
Software:
LiveWire:-Used for schematic diagrams designing
PCB Wizard:-Used for PCB layouts
Theory:
The full wave rectifier circuit consists of two power diodes connected to a single load resistance
(RL) with each diode taking it in turn to supply current to the load. When point A of the transformer is
positive with respect to point C, diode D1 conducts in the forward direction as indicated by the arrows.

When point B is positive (in the negative half of the cycle) with respect to point C, diode D2 conducts in the
forward direction and the current flowing through resistor R is in the same direction for both half-cycles. As
the output voltage across the resistor R is the phasor sum of the two waveforms combined, this type of full
wave rectifier circuit is also known as a “bi-phase” circuit.

Procedure:

1.Connect the circuit as for the circuit diagram.

2.Connect the supply to the full wave rectifier.
3.Apply the value.
4. Check the OUTPUT.
Outcomes
• Received an unparalleled education on the art of PCB designing with personal
one-on- One attention
• The circuit designing in the Proteus software and can design their own circuits.
• Design Schematic of the circuit In Proteus Ares • Selection of Foot Prints for the
Components in CVPCB
• Plotting Gerber files
• Hands on experience in PCB Fabrication
➢ Toner transfer method
➢ Etching Process
➢ Drilling and Placement of Components
➢ Soldering And testing of the Circuit

Benefits of attending Skill Oriented Course

Learn & Interact with renowned Industry Experts.
➢ Receive an unparalleled education on the art of PCB designing with personal
one on-one attention.
➢ Covers all the basics of PCBs.
➢ Softcopy developed by well-established Industry experts (through E-mail). ➢
Hands-On Experience of Latest PCB Techniques & Tools. All the necessary
software & Hardware would be provided.