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PCB Fabrication

Introduction

Welcome to Workshop 4! Now that you’ve mastered soldering techniques, it’s time to create your own custom Printed Circuit Board (PCB) using a PCB milling machine. This workshop will introduce you to the exciting world of PCB fabrication, where you’ll design and mill your very own board from scratch. If you’ve ever wondered how to turn your electronics designs into real, functional hardware, you’re in the right place. Let’s get hands-on and mill some PCBs!

Objective

In this workshop, you’ll learn how to fabricate a PCB using a milling machine. By the end of the session, you will:

  • Understand the process of turning a digital PCB design into a physical board.
  • Learn how to set up and operate a PCB milling machine safely and effectively.
  • Create a functional PCB that’s ready for soldering and testing.
  • Gain a better appreciation for the PCB design and fabrication process in electronics prototyping.

Tools & Equipment

Here’s what you’ll be using during the workshop:

PCB Milling Machine

 

 

The main tool used to carve out the copper traces on your board.

Copper Clad Board

 

This is the raw material that will be milled to create your PCB.

Gerber Files

 The industry-standard files exported from PCB design software, containing the information needed for the milling machine to create the traces.

Tape

Used to secure the copper-clad board to the milling machine bed.

         

Milling Bits

 

Tiny bits that cut away the copper, creating the traces on your PCB.

Tools & Equipment Safety

Using a milling machine involves safety precautions, so make sure you follow these tips:

  • Machine Safety: Keep hands and clothing away from moving parts while the machine is in operation. DO NOT OPEN THE COVER while the machine is running
  • Eye Protection: Always wear safety goggles to protect your eyes from any copper or debris that might come loose.
  • Air Management System: This system helps maintain clean air quality while milling, minimizing the risk of inhaling dust and debris.
  • Handling Tools: After milling, the board might have sharp edges, so handle it carefully and use tools to clean off the debris.
  • Workstation Clean-Up: After milling, clean up your workspace, removing any copper dust or debris, and store the milling bits properly.

Project: Variable DC-DC Regulator

In this project, you’ll start by loading a copper-clad board into the PCB milling machine. Using the Gerber files prepared, the machine will precisely mill out the copper traces, leaving you with a custom PCB! Once the board is complete, you’ll clean it up and inspect it for any errors. This is an exciting step in the electronics prototyping journey because now you’ll have a functional, customized PCB ready for assembly in future workshops. Plus, you’ll have learned a skill that brings your designs to life!