Rapid prototype PCB engraving

I didn't discover anything new here, but it is relatively new to me. I was pretty stoked to find out how easy and cheap it is to engrave your own PCBs, and obviously I wanted to share my "new discovery."

What I use is a 12.00 rotary engraving tool and some half ounce pour FR-4 copper clad board. I found a source for copper clad for pennies per sheet. With these tools I can say goodbye to protoboard and jumper wires forever.

Now don't get me wrong. This won't replace etching, but this method will be quicker for very simple one-off circuits and modifications and it is unique in that you can literally build the circuit as you go. This is great news for evil scientists with ADHD. And the process leaves lots of blank copper, so you can go back later and add components that you might have overlooked or hadn't thought of at the time.

Step 1 Materials

The circuit I am copying is a simple fixed-current circuit that was created and posted here:
http://www.afrotechmods.com/reallycheap/batteries/batts.htm

No doubt you just spend 30 minutes browsing this very entertaining site. Welcome back and let's get down to business.

The electrical components I used are as follows:

SIP header
1x 2n3904 npn transistor
2x 4148 signal diodes
1x 9.5k smd resistor
1x 11R smd resistor

Comments

[wubs]

Can you upload the video to YouTube? For whatever reason, I cannot view anything on Metacafe using either FireFox or IE.

[klee27x]

Hey, sorry. I don't know how I missed this comment. Umm. Well, let's just say it's quite a bit slower than, say, drawing it out with a permanent marker. But for small stuff, it can save a lot of time, because you don't have to etch. I also do pcb etching using toner transfer method and the permanent marker techique (Staedtler Lumocolor are the best!). It all depends on what it's for. My basic strategy goes as follows: Toner transfer: If I need a lot of copies, or if it's complex Sharpie: not too complex, and I only need one Engraving: really simple circuit, adaptor, etc, or modding other circuits/stuff.

[paulm]

this is a cool idea, I think I will give it a whirl for my rather simple capacitor charging circut

[klee27x]

Just try to get 1/2 oz copper pour. It's a lot easier with the thin stuff.

[technodude92]

could i do this with a Dremel? I have a nifty flexible extension and have been looking for a good use for it.

[klee27x]

I have a Dremel Stylus. With a fine engraving tip running at 4-6K rpm, it makes slightly finer lines and cuts twice as fast as this tool. I just SLIGHTLY prefer this tool, because it doesn't vibrate as much and you can hold it like a pen. I've never used the extension you've got, but it might actually be the perfect thing.

[klee27x]

Oh, I have a basic, single speed Dremel, too, and I'd say it's not worth trying with one of those. Your lines will be all over the place and you'll go deaf before you finish anything. :)

[leather]

Where did you get the boards for cheap?

[klee27x]

Some dude on Ebay. He's been in business quite awhile. Here's a link to one of his auctions. IIRC, one of my purchases was like 48 pieces of 4"x9" (>5 pounds of boards) 0.60 FR-4, doublesided, 1/2 ounce pour for like 36.00. (To me, anything under a buck equates to pennies per... I mean what else would you say? "Quarters per sheet?") :)

http://cgi.ebay.com/10-shts-Copper-Clad-Laminate-FR-4-060-6-3-8-x-8_W0QQitemZ310091047750QQcmdZViewItem?hash=item310091047750&_trkparms=72%3A1419|39%3A1|66%3A2|65%3A12|240%3A1318&_trksid=p3911.c0.m14

One of my shipments was spotless and shiny, but the rest had a good number of fingerprints or spots on most of the boards. But they all shine up really easy. They are also cutoffs (at least the ones I bought, maybe the more expensive auctions aren't).. so there are not all perfectly true to size. My ferric chloride etches have been coming out really nice, too.

[leather]

thanks a heap for the link. I want to start dabbling with PCBs, and cheap parts help!

[klee27x]

(removed by author or community request)

[klee27x]

Here's what the 0.60 FR-4 looks like. It's rather pretty underneath all that copper:

[HOWITZER]

hey its to pretty

[klee27x]

Here are a few other very small/simple circuits that ended up looking pretty tidy. On the alarm circuit in the middle, it's amazing how many things/parts I overlooked and was able to add after soldering all the other stuff on there. And I only ended up with two very short jumpers.