Multilayer PCB fabrication is a very sophisticated process in particular when many layers are involved on a small sizing motherboard. As the devices are getting smaller and even smaller – determined by simply the ergonomics features how the consumer expects – we are required to fit additional factors per square in. than ever. Circuit set up turns into a task. Although by using modern personal computer computer software it is fairly straightforward to design a great electronic scheme and print it by advanced etching techniques, is actually when the layers own to add up that many of us can be faced with problems.
If the copper sheets are not aligned perfectly, the whole system will fail to work because the current won’t flow between the sheets or the wrong points will come into contact. The circuit will malfunction, reducing all the design effort to nothing.
Earlier the manufacturers of multilayer PCB used mechanical contact methods to align layers. Now it is much more easier. With imaging systems it is possible to use cameras to align the layers top to bottom and if imprecision is detected, they can be positioned in order to fit properly.
Many manufacturers are gradually adopting the so-called Perfect Test system to achieve a top precision layer alignment. It determines the actual position of each inner sheet to 0.001-inch accuracy. By testing a certain number of prototype printed circuit boards, the test system determines the average design clearance between the pattern and holes that connect the sheets. The results are processed and then when you start the actual production process, the system will have calculated the best alignment and give you high precision multilayer PCB products that you’ll be proud of.
Getting the prototype spot on is a huge step towards a superior product. Unfortunately, many manufacturers try to get through this important stage of production as quickly as possible. The aforementioned methods are not cheap but they are essential.
Each electronics company starting out or trying to improve their quality control has to consider what to use to make sure their product stands out. The competition in electronics sector is fierce and in the long run the best quality always wins.
Using copper clad boards is one of the most cost-effective ways to create hobby or prototype printed circuit boards (PCB). A copper-clad board is a laminate of non-conductive substrate (often fiberglass and epoxy) and copper, that is used to create printed circuit board tracks that connect components of a circuit soldered to it. PCB prototype fabrication service is quite cheap, and they can be made into professional-looking boards with simple household materials.
Cheap: Creating your board from a copper-clad is most often cheaper than ordering a prototype batch from a PCB manufacturer since they often charge a setup fee or base price, which when buying a large volume isn’t a problem since it represents a small percentage of the overall order, but when buying one or two boards it can be as much as ten times the cost of a copper-clad, plus shipping.
Fast: Ordering from a manufacturer can take a long time. Most orders are shipped in five to six days for the basic shipping option, but if you need a board fasts you can expect to pay quite a lot more, and it still takes two or three days to arrive. Making a board from a copper-clad is very fast, especially if you already have the materials needed at home or in the lab.
Customizable: Developing your own copper clad boards has the great advantage of creating custom shapes and sizes, thing that most manufacturers can’t (or won’t) do, or will charge exorbitant fees. This gives you the flexibility to make your circuits fit into odd shapes, or making really small boards.