Multilayer PCB Printed Circuit Board Green 6oz Electronics PCB PCBA 3mil
Printed circuit direct current around their surface through a network of copper pathways.The complex system of copper routes determines the unique role of each piece of electronic board.Printed Circuit Boards -PCB form the backbone of all major electronic product. And the PCBs used in nearly all computational electronics, From the simple devices like digital clocks, calculators etc. A Printed circuit board routes electrical signals through electronics, which satisfies the device's electrical and mechanical circuit requirements. In short, PCB tell the electricity where to go, bringing your electronics to life.
PCB Manufacturing Process Steps
Step 1: PCB Layout and Output
Electronic boards should be rigorously compatible with, a PCB layout created by the designer using PCB design software. Commonly-used PCB design software includes Eagle,Altium Designer, OrCAD, Pads, KiCad, etc.
NOTE: The most common used PCB software by the PCB Manufacturer is AD DXP PROTEL CMA350 PADS ect,Before PCB manufacturing, designers should inform their contract manufacturer about the PCB design software version used to design the circuit since it helps avoid issues caused by discrepancies.
Once the PCB design is approved for production, designers export the design into format their manufacturers support. The most frequently used program is called extended Gerber.Gerber also goes by the name IX274X.Different generation of Gerber software,They all encode comprehensive vital information including copper tracking layers, drill drawing, apertures, component notations and other options.All aspects of the PCB design undergo checks at this point. The software performs oversight algorithms on the design to ensure that no errors go undetected. Designers also examine the plan with regard to elements relating to track width, board edge spacing, trace and hole spacing and hole size.
After a thorough examination, designers forward PCB file to PCB Fabricator for manufacturing. To ensure the design fulfills requirements for the minimum tolerances during manufacturing process, almost all PCB manufacturer run Design for Manufacture (DFM) check before circuit boards fabrication.
Step 2: From File to Film- map out a figure of copper path
The PCB manufacturers use a special printer called a plotter, which makes photo films of the PCBs, to print circuit boards. Manufacturers will use the films to image the PCBs. Although it's a laser printer, it isn't a standard laser jet printer. Plotters use incredibly precise printing technology to provide a highly detailed film of the PCB design.
Step 3: Making the Inner layers - Print the figure on the film onto a copper foil.
This step in PCB fabricating prepares to make actual Printed circuit board. The basic form of PCB (printed circuit board) comprises a laminate board whose core material is epoxy resin and glass fiber that are also called substrate material. Laminate serves as an ideal body for receiving the copper that structures the PCB. Substrate material provides a sturdy and dust-resistant starting point for the PCB. Copper is pre-bonded on both sides. The process involves whittling away the copper to reveal the design from the films.
In PCB (printed circuit board) construction, cleanliness does matter. The copper-sided laminate is cleaned and passed into a decontaminated environment. During this stage, it's vital that no dust particles settle on the laminate. An errant speck of dirt might otherwise cause a circuit to be short or remain open.
Next, the clean panel receives a layer of photo-sensitive film called photo resist. The photo resist comprises a layer of photo reactive chemicals that harden after exposure to ultra violet light. This ensures an exact match from the photo films to the photo resist. The films fit onto pins that hold them in place over the laminate panel.The film and board line up and receive a blast of UV light. The light passes through the clear parts of the film, hardening the photo resist on the copper underneath. The black ink from the plotter prevents the light from reaching the areas not meant to harden, and they are slated for removal.
After the PCB board becomes prepared, it is washed with an alkaline solution that removes any photo resist left unhardened. A final pressure wash removes anything else left on the surface. The board is then dried.
The product emerges with resist properly covering the copper areas meant to remain in the final form. A technician examines the boards to ensure that no errors occur during this stage. All the resist present at this point denotes the copper that will emerge in the finished PCB(printed circuit board).This step only applies to boards with more than two layers. Simple two-layer boards skip ahead to drilling. Multiple-layer boards require more steps.
Step 4: Removing the Unwanted Copper
With the photo resist removed and the hardened resist covering the copper we wish to keep, the board proceeds to the next stage: unwanted copper removal. Just as the alkaline solution removed the resist, a more powerful chemical preparation eats away the excess copper. The copper solvent solution bath removes all of the exposed copper. Meanwhile, the desired copper remains fully protected beneath the hardened layer of photo resist.
Not all copper boards are created equal. Some heavier boards require larger amounts of copper solvent and varying lengths of exposure. As a side note, heavier copper boards require additional attention for track spacing. Most standard PCBs rely on similar specification.
With all the layers clean and ready, the layers require alignment punches to ensure they all line up. The registration holes align the inner layers to the outer ones. The technician places the layers into a machine called the optical punch, which permits an exact correspondence so the registration holes are accurately punched.
Once the layers are placed together, it's impossible to correct any errors occurring on the inner layers. Another machine performs an automatic optical inspection of the panels to confirm a total absence of defects. The original design from Gerber, which the manufacturer received, serves as the model. The machine scans the layers using a laser sensor and proceeds to electronically compare the digital image with the original Gerber file.
If the machine finds inconsistency, the comparison is displayed on a monitor for the technician to assess. Once the layer passes inspection, it moves to the final stages of PCB production.
Step 6: Layer-up and Bond
In this stage, the circuit board takes shape. All the separate layers await their union. With the layers ready and confirmed, they simply need to fuse together. Outer layers must join with the substrate. The process happens in two steps: layer-up and bonding.
The outer layer material consists of sheets of fiber glass, pre-impregnated with epoxy resin. The shorthand for this is called prepreg. A thin copper foil also covers the top and bottom of the original substrate, which contains the copper trace etchings. Now, it's time to sandwich them together.
The bonding occurs on a heavy steel table with metal clamps. The layers securely fit into pins attached to the table. Everything must fit snugly to prevent shifting during the alignment.
A technician begins by placing a prepreg layer over alignment basin. The substrate layer fits over the prepreg before the copper sheet is placed. Further sheets of prepreg sit on top of the copper layer. Finally, an aluminum foil and copper press plate complete the stack. Now it's prepped for pressing.
The entire operation undergoes an automatic routine run by the bonding press computer. The computer orchestrates the process of heating up the stack, the point in which to apply pressure, and when to allow the stack to cool at a controlled rate.
Next, a certain amount of unpacking occurs. With all the layers molded together in a super sandwich of PCB glory, the technician simply unpacks the multi-layer PCB product. It's a simple matter of removing the restraining pins and discarding the top pressure plate. The PCB goodness emerges victorious from within its shell of aluminum press plates. The copper foil, included in the process, remains to comprise the outer layers of the PCB.
Step 7: Drilling
Finally, holes are bored into the stack board. All components slated to come later, such as copper-linking via holes and leaded aspects, rely on the exactness of precision drill holes. The holes are drilled to a hairs-width - the drill achieves 100 microns in diameter, while hair averages at 150 microns.
To find the location of the drill targets, an x-ray locator identifies the proper drill target spots. Then, proper registration holes are bored to secure the stack for the series of more specific holes.
Before drilling, the technician places a board of buffer material beneath the drill target to ensure a clean bore is enacted. The exit-material prevents any unnecessary tearing upon the drill's exits.
A computer controls every micro-movement of the drill - it's only natural that a product that determines the behavior of machines would rely on computers. The computer-driven machine uses the drilling file from the original design to identify the proper spots to bore.
The drills use air-driven spindles that turn at 150,000 rpm. At this speed, you might think that drilling happens in a flash, but there are many holes to bore. An average PCB contains well over one hundred bore intact points. During drilling, each needs its own special moment with the drill, so it takes time. The holes later house the vias and mechanical mounting holes for the PCB. The final affixation of these parts occurs later, after plating.
Step 8: Plating and Copper Deposition
After drilling, the panel moves onto plating. The process fuses the different layers together using chemical deposition. After a thorough cleaning, the panel undergoes a series of chemical baths. During the baths, a chemical deposition process deposits a thin layer - about one micron thick - of copper over the surface of the panel. The copper goes into the recently drilled holes.
Prior to this step, the interior surface of the holes simply exposes the fiber glass material that comprises the interior of the panel. The copper baths completely cover, or plate, the walls of the holes. Incidentally, the entire panel receives a new layer of copper. Most importantly, the new holes are covered. Computers control the entire process of dipping, removal and procession.
Step 9: Outer Layer Imaging
In Step 3, we applied photo resist to the panel. In this step, we do it again - except this time, we image the outer layers of the panel with PCB design. We begin with the layers in a sterile room to prevent any contaminants from sticking to the layer surface, then apply a layer of photo resist to the panel. The prepped panel passes into the yellow room. UV lights affect photo resist. Yellow light wavelengths don't carry UV levels sufficient to affect the photo resist.
Black ink transparencies are secured by pins to prevent misalignment with the panel. With panel and stencil in contact, a generator blasts them with high UV light, which hardens the photo resist. The panel then passes into a machine that removes the unhardened resist, protected by the black ink opacity.
The process stands as an inversion to that of the inner layers. Finally, the outer plates undergo inspection to ensure all of the undesired photo resist was removed during the previous stage.
Step 10: Plating
We return to the plating room. As we did in Step 8, we electroplate the panel with a thin layer of copper. The exposed sections of the panel from the outer layer photo resist stage receive the copper electro-plating. Following the initial copper plating baths, the panel usually receives tin plating, which permits the removal of all the copper left on the board slated for removal. The tin guards the section of the panel meant to remain covered with copper during the next etching stage. Etching removes the unwanted copper foil from the panel.
Step 11: Final Etching
The tin protects the desired copper during this stage. The unwanted exposed copper and copper beneath the remaining resist layer undergo removal. Again, chemical solutions are applied to remove the excess copper. Meanwhile, the tin protects the valued copper during this stage.The conducting areas and connections are now properly established.
Step 12: Solder Mask Application
Before the solder mask is applied to both sides of the board, the panels are cleaned and covered with an epoxy solder mask ink. The boards receive a blast of UV light, which passes through a solder mask photo film. The covered portions remain unhardened and will undergo removal.Finally, the board passes into an oven to cure the solder mask.
Step 13: Surface Finish
To add extra solder-ability to the PCB, we chemically plate them with gold or silver. Some PCBs also receive hot air-leveled pads during this stage. The hot air leveling results in uniform pads. That process leads to the generation of surface finish. PCBCart can process multiple types of surface finish according to customers' specific demands.
Step 14: Silkscreen
The nearly completed board receives ink-jet writing on its surface, used to indicate all vital information pertaining to the PCB. The PCB finally passes onto the last coating and curing stage.
Step 15: Electrical Test
As a final precaution, a technician performs electrical tests on the PCB. The automated procedure confirms the functionality of the PCB and its conformity to the original design. At PCBCart, we offer an advanced version of electrical testing called Flying Probe Testing, which depends on moving probes to test electrical performance of each net on a bare circuit board.
Step 16: Profiling and V-Scoring
Now we've come to the last step: cutting. Different boards are cut from the original panel. The method employed either centers on using a router or a v-groove. A router leaves small tabs along the board edges while the v-groove cuts diagonal channels along both sides of the board. Both ways permit the boards to easily pop out from the panel.
1. Our Services
1. PCB fabrication.
2. Turnkey PCBA: PCB+components sourcing+SMD and through-hole assembly
3. PCB clone, PCB reverse engineering.
PCB or PCBA Files Requests:
1. Gerber files of the bare PCB board
2. BOM (Bill of material) for assembly (please kindly advise us if there is any acceptablecomponents substitution.)
3. Testing Guide & Test Fixtures if necessary
4. Programming files & Programming tool if necessary
5. Schematic if necessary
2. Company Information
Global Well Electronic Inc. is a professional PCB solution supplier from Shenzhen, China, integrating PCB circuit board production and processing, STM processing and mounting, PCBA OEM, component purchasing, PCB/PCBA custom design-production- A comprehensive PCB circuit board company with one-stop turnkey service of processing-assembly-finished products. The company has a strong supply chain system, a professional and efficient collaborative team, a sound and complete quality control system, and the business philosophy of honesty and trustworthiness, customer first, and presents the products to everyone with low prices, reliable quality, high-quality service and after-sales service. client.
We provide total PCB solutions from PCB design to final mass production, including PCB fabrication and assembly, component sourcing, solder paste stencils, conformal coatings, and more. Serving the global electronics field, including industrial control, medical electronics, military equipment, power communication, automotive electronics, AI artificial intelligence, smart home and other industries.
Our factory located in Shenzhen, and have almost 300
employees, more than 30 production lines include SMT, DIP, automatic welding, aging test and assembly. We have SMT machines from Japan and Korea, automatic solder paste printing machines, solder paste inspection machine(SPI)12 temperature zone reflow soldering machine, AOI detector, X-RAY detector, wave soldering machine, EM PCB ,dispenser,laser print machine etc., Different line configurations can meet requirements from small sample order to bulk shipment.
Our company has obtained ISO 9001 quality system certification and ISO 14001 system certification. With multi-testingprocedures, our products carry out the quality system standard strictly.
3. Main Equipment:
4. PCB Technical Specification
(1) PCB Technical Specification
|Order Quantity||1-300,000,30000 Square Meter/Square Meters per Month module electronic board|
|Layer||1,2,4,6,upto 24 layer|
|Material||FR-4,glass epoxy,FR4 High Tg,Rohs compliant,Aluminum,Rogers,etc|
|Shape||Any shape: Rectangular,round,slots,cutouts,complex,irregular|
|Max PCB dimensions||20inch*20inch or 500mm*500mm|
|Thickness||0.2~4.0mm, Flex 0.01~0.25''|
|Thickness tolerance||± 10%|
|Copper thickness||0.5-4 oz|
|Copper thickness tolerance||± 0.25oz|
|Surface finish||HASL,Nickle,Imm Gold,Imm Tin,Imm Silver,OSP etc|
|Solder mask||Green, red,white,yellow,blue,black, Double-sided|
|Silk screen||White,yellow,black,or negative, Double-sided or single-sided|
|Silk screen min line width||0.006'' or 0.15mm|
|Min drill hole diameter||0.01'',0.25mm.or 10 mil|
|Min trace/gap||0.075mm or 3mil|
(2) Turnkey PCBA Capabilities
|Turnkey PCBA||PCB+components sourcing+assembly+package|
|Assembly details||SMT and Thru-hole, ISO lines|
|Lead Time||Prototype: 15 work days. Mass order: 20~25 work days|
|Testing on products||Flying Probe Test, X-ray Inspection, AOI Test, functional test|
|Quantity||Min quantity: 1pcs. Prototype, small order, mass order, all OK|
|Files we need||PCB: Gerber files(CAM, PCB, PCBDOC)|
|Components: Bill of Materials(BOM list)|
|Assembly: Pick-N-Place file|
|PCB panel Size||Min size: 0.25*0.25 inches(6*6mm)|
|Max size: 20*20 inches(500*500mm)|
|PCB Solder Type||Water Soluble Solder Paste, RoHS lead free|
|Components details||Passive Down to 0201 size|
|BGA and VFBGA|
|Leadless Chip Carriers/CSP|
|Double-sided SMT Assembly|
|Fine Pitch to 0.8mils|
|BGA Repair and Reball|
|Part Removal and Replacement|
|Component package||Cut Tape,Tube,Reels,Loose Parts|
Soldering-----Assembling-----ICT-----Function Testing-----Temperature - Humidity Testing
5. PCB&PCBA Products Show
7. Packaging & Shipping
PCBA are packed into plastic bags. Plastic bags are put into small carton. 4 small carton into a big carton.
A big carton: 35×32×40 cm size.
FedEx, DHL, UPS, TNT, EMS, private lines, etc.
Air freight, Sea shipping
If you need help on PCB layout, you can contact us and send the board to us. We also provide Reverse Engineering Service.
We have been providing PCB Manufacture for many years in China,and we have rich experience in product production and product assembly.We believe our team will provide high quality and low cost service for you.
Thank you very much for all your support .
Q1.What is needed for PCB PCBA quotation?A: PCB: Quantity, Gerber file and Technic requirements(material,surface finish treatment,
copper thickness,board thickness ,...)
PCBA: PCB information, BOM, (Testing documents...)
Q2. What file formats do you accept for PCB PCBA production?
A: Gerber file: CAM350 RS274X
PCB file: Protel 99SE, P-CAD 2001 PCB
BOM: Excel (PDF,word,txt)
Q3. Are my files safe?
A: Your files are held in complete safety and security.We protect the intellectual property for our customers in the whole
process.. All documents from customers are never shared with any third parties.
A: There is no MOQ in STG .We are able to handle Small as well as large volume production with flexibility.
A: The shipping cost is determined by the destination, weight, packing size of the goods. Please let us know if you need us to quote you the shipping cost.Besides ,we can ship the cargos to your own forwarder if you have in China
Q6. What service do you have?