How to make a PCB

I tried many methods over the years, but i am currently using the cold transfer method to transfer the design to the PCB before etching.

This method uses aceton to make the toner stick to the PCB. I buy my aceton from Jumbo stores here in Greece as it is very cheap (3-4 euros per 1lt) and it does the job quite good. It is not 100% aceton so if you have some other product be sure to dilute it with water or alcohol, if it is too strong.

Step 1

Design your PCB. Make sure you use the bottom layer to do so, Also if you want to have text on this layer you should mirror the letters horizontally.

Step 2

Print the PCB on an inkjet Photo glossy paper. I am using M-real data glossy (just happen to have it) but any glossy should work.

Step 3

Cut the paper around the design. Cut the board if necessary a little bigger than the design 2-3mm should be enough. Use your Dremel to sand the edge.

Step 4

Use steel wool pads (Kitchen wire cleaning) to sand the board thorougly. Clean it by using soap water, alcohol or aceton.

Step 5 – Toner transfer

Pour some aceton to the board and make sure to fully cover it with a thin layer. Put the Glossy paper on the board and align it properly.

After 20 seconds or so start putting pressure on the paper from one side to the other left to right and top to bottom.

I am using a cylinder i 3d printed for this purpose, it helps a lot to apply pressure evenly.

You can also pour some aceton on the paper if you think it needs more ( i usually do). Let it stay for a couple of minutes.

Step 6

Soak the paper in some warm soapy water, leave it there for 5 minutes to soak well and gently start rubbing the paper under water. The paper should disintegrate and all that should be left on the board is the toner. If some tracks get destroyed you can re-touch some areas with a permanent marker.

*** At this point i must say that my paper leaves the glossy layer intact and it must be removed before etching. I usually use a small screwdriver to remove this layer by gently scratching it inside the water. I hope other glossy papers don’t leave this layer on the pcb.

You can see the glossy layer that needs to be removed, unfortunately it is water proof.

Step 7 – Etching

I am using ready made Ferric chloride (F_eCl₃) 1lt bottle.

I use a sponge and scrub the pcb as i am pouring small amounts of ferric chloride. This way the etching is faster and you are using far less amount than dipping the pcb on the ferric chloride and wait for it to dissolve the copper.

If you use kitchen sponge use gloves to protect your hands.

Step 8

After etching you should clear the board using water and remove the toner either by using aceton or by scrubbing it with the steel wool pads under water.

Step 9

Test your board for continuity or short circuits and repair any problems, then drill it, and popullate the pcb with the components for soldering.

Step 10

Re test your board for continuity or short circuits and repair any problems, then power it up.

Double sided PCBs

For double sided pcbs use the same method but do this after Step 5

Step 5a

Print the top layer using mirror, and cut it like the bottom one

Step 5b

Drill 6-7 holes on the pcb, spread them all over the pcb, and put long pins through them.

Step 5c

Align the top paper using the pins but leave some space between the pcb and the paper, don’t put it all the way down yet.

Step 5d

Carefully pour some aceton on the copper side (the other side should be on the bottom and protected, put the pcb on a soft paper) and touch the top paper to the pcb lowering it through the pins. When it touches the pcb it should stick to it because of the aceton.