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Manufacturing Process

PCB
Production

What is a PCB?

A Printed Circuit Board (PCB) is the foundation of almost every electronic device. It is a flat board made from fiberglass-reinforced epoxy laminate or other composite materials.The PCB mechanically supports and electrically connects electronic components using conductive copper tracks etched onto its surface.From mobile phones and computers to industrial machines and medical devices — PCBs are the backbone of modern electronics.Explore our Blogs to know about PCB related Queries

PCB Manufacturing Process

Step by Step Guide

Below is a simplified overview of how a PCB is manufactured in a professional production facility.

Step 1

Design & Data Preparation

The process begins when we receive the customer's Gerber files and design data.

Our engineering team:

  • Verifies track widths and spacing
  • Checks pad sizes and annular rings
  • Reviews hole diameters
  • Confirms manufacturing feasibility
  • Validates copper clearances

After verification, production tool files are generated to control drilling, imaging, plating, and testing machines.

Step 2

Film Generation (Photoplotting)

Using high-precision laser photoplotters in a temperature-controlled darkroom, we convert design data into film artwork.

These films represent each PCB layer and are:

  • Developed automatically
  • Aligned accurately
  • Punched with registration holes
  • Prepared for imaging processes

This ensures precise layer alignment during production.

Step 3

Inner Layer Imaging (For Multilayer PCBs)

For multilayer boards:

  • Copper-clad laminate is coated with photoresist.
  • UV light transfers the circuit pattern onto the panel.
  • Unwanted resist is removed.
  • Exposed copper is etched away.
  • Remaining photoresist is stripped.

After etching, the exact copper circuitry remains on the inner layers.

Each inner layer undergoes Automated Optical Inspection (AOI) to detect defects before proceeding further.

Step 4

Layer Alignment & Lamination

For multilayer boards:

  • Inner cores are stacked with prepreg (epoxy resin sheets) and copper foils.
  • The stack is aligned using registration pins.
  • Panels are placed under high heat and pressure.
  • Epoxy resin melts and bonds layers permanently.

This creates a solid multilayer PCB structure.

Advanced PCBs may contain 4, 6, 8 or even 50+ layers depending on application requirements.

Step 5

Drilling

CNC drilling machines create:

  • Plated-through holes (PTH)
  • Non-plated mounting holes
  • Via holes for interlayer connections

All drilling is performed using CAD-generated programs for high precision.

Step 6

Hole Metallization (Plating Through Holes)

To establish electrical connections between layers:

  • Holes undergo chemical cleaning.
  • A thin layer of copper is deposited using electroless plating.
  • Additional copper is built up through electroplating.

This ensures strong electrical conductivity across layers.

Step 7

Outer Layer Imaging

Both sides of the board are coated with photoresist.

  • UV exposure transfers the outer layer circuit pattern.
  • Unexposed areas are removed.
  • Copper is electroplated to required thickness.
  • Tin plating protects circuit traces during etching.
Step 8

Etching

Unwanted copper is chemically removed, leaving only the required circuit pattern.

After etching:

  • Protective layers are stripped.
  • The basic circuitry of the PCB is completed.
Step 9

Solder Mask Application

A protective Liquid Photo Imageable (LPI) solder mask is applied to both sides.

The solder mask:

  • Protects copper traces from oxidation
  • Prevents solder bridging
  • Improves insulation
  • Enhances board durability

Only solder pads remain exposed for component mounting.

Step 10

Silkscreen (Legend Printing)

Component markings, reference labels, logos, and identification details are printed on the board using a silkscreen process.

This helps in assembly and troubleshooting.

Step 11

Routing / Profiling

The PCB panel is cut into individual board shapes using CNC routing machines.

For panelized boards:

  • V-cut (V-score)
  • Break routing (tab routing)

may be used for separation.

Step 12

Electrical Testing

Each PCB undergoes electrical testing to verify:

  • No open circuits
  • No short circuits
  • Correct electrical connectivity

Using specialized test fixtures, every net is checked for continuity and integrity.

Step 13

Final Inspection & Quality Control

Before shipping, boards go through:

  • Visual inspection
  • Dimensional verification
  • Surface finish check
  • 100% quality audit

Only boards that meet all standards are packed and dispatched to customers.