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Printed circuit boards are usually manufactured by chemical etching (with iron (III) chloride or ammonium persulfate, for example). This is not very practical if only a few boards are necessary, because these etchants are messy and somewhat dangerous. PCBs can also be manufactured by "mechanical etching," in which a trace is "etched" by milling away the copper along its perimeter. This requires software to generate a toolpath from the layout and a small CNC mill or router. Lots of companies make routers for PCB fabrication, but they are unjustifiably expensive so I decided to build one.
April 22, 2011 By Mike Szczys 23 Comments Printed circuit board milling PCB milling
Why should you mill PCBs?
Did you know that there is an alternative way to obtain high-quality PCBs at a good price? Although speed is vitally important in today’s competitive market, you spend most of your time waiting for suppliers. Making your own PCBs using a chemical process is environmentally unfriendly, and in most cases it is prohibited. If you nevertheless want to use a chemical process, your are confronted with very large investment costs if you want to achieve the same quality as milled PCBs.
Milling prototype PCBs is the fastest and most economical solution.
The downside of outsourcing
PCB manufacturers can supply prototype boards faster and at lower prices than in the past, but they can never match the flexibility and cost of milling your own PCBs in-house. Although PCB milling is not suitable for large production volumes, outsourcing is too slow and expensive for small volumes. We can illustrate this with an example.
Flexitronic received an order to develop a blood analysis instrument. As usual, the time to market had to be as short as possible. They needed a total of six PCBs. Each time a board design was completed, it was ordered with great haste from a PCB manufacturer. The delivery time for each board was five working days. The total delivery time was thus approximately twenty working days, which was at the limit of what was acceptable. There was a problem with one of the boards, with the result that the completed boards were finally ready on the assembly bench two months later. The cost of PCB production was 1332 euros. During initial testing, it was found that some software changes were necessary, with the result that more memory was needed on the motherboard, and there were minor errors with two of the other boards. Ramping up series production without a second round of testing was entirely unacceptable. Three new prototype boards were thus ordered, at a cost of 1105 euros. Four weeks later they were fully assembled and could be tested again. The new boards were OK, and the production run could be ordered.
From Wikipedia, the free encyclopedia
Milled Printed Circuit Board
Printed circuit board milling is the process of removing areas of copper from a sheet of printed circuit board material to recreate the pads, signal traces and structures according to patterns from a digital circuit board plan known as a layout file. Similar to the more common and well known chemical PCB etch process, the PCB milling process is subtractive: material is removed to create the electrical isolation and ground planes required. However, unlike the chemical etch process, PCB milling is typically a non-chemical process and as such it can be completed in a typical office or lab environment without exposure to hazardous chemicals. High quality circuit boards can be produced using either process. In the case of PCB milling, the quality of a circuit board is chiefly determined by the system's true, or weighted, milling accuracy and control as well as the condition (sharpness, temper) of the milling bits and their respective feed/rotational speeds. By contrast, in the chemical etch process, the quality of a circuit board depends on the accuracy and/or quality of the photomasking and the state of the etching chemicals.
[Juan Jose Chong] put together a set of videos and a PDF guide to milling printed circuit boards. You’ll find the pair of videos, totaling about twenty-two minutes, embedded after the break. In them, [Jaun] details the techniques used by the IEEE chapter at Texas Tech University to mill PCBs instead of using the traditional method of etching them. We’ve long been a fan of milled PCBs and often dream about the day we can retire the old iron we
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Cabinet (requires assembly) is available as an optional item.
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LPKF's ProtoMat family of systems provides an ideal PCB prototyping machine for virtually any engineering environment. Every LPKF ProtoMat® PCB prototyping machine is built to be the best of its class, with thousands of installed quickturn systems to prove it. Each PCB milling machine system has its own special system features. Some prototype milling machines feature milling, drilling, routing and depanelization; some feature a new generation of advanced boards and circuit board plotters. Other prototype milling machines have automatic tool change and are ideal for exotic substrates and flex.
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~Mr. Tomokazu Wantanave, DENSO Corp.
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