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Exp-6_ PCB design using CNC machine

Aim: Fabrication of PCB using CNC machine
A printed circuit board or PCB, in general, is manufactured by using the etching method or the
wet method. This method is a non-chemical copper removal process so that PCB fabrication can
be done in a lab environment without hazardous chemicals. There are no hard and fast rules for
this type of PCB manufacturing CNC Machines. However, the prototyping articles or prototype
PCBs can be produced using the CNC engraving machines.

 It involves two steps.

1: Schematic Diagram
 You must start with creating a schematic diagram using and CAD/Eagle software.
 Schematic diagram gives clear overview what kind of components you would be using in
your design and how they are connected with different paths and traces.
 This diagram won’t indicate the actual path that you would be transferring on the actual
copper board, because lines and paths you use creating a schematic diagram can be
differently aligned on the PCB board.
 Schematic is only for giving knowledge that even common man can anticipate how different
components are connected on the boards.
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2: PCB Layout Designing

 Next step is making a PCB layout design. This design will define the actual
circuit design that will be incorporated on the copper board.
 There are many software you can use to create PCB layout design including
PCBWizard, Cadsoft Eagle, Proteus and many more.
 PCB layout design covers less space than schematic diagram and it can be
easily placed in a tight space based on your requirements.
 Be careful when you create PCB layout design and avoid the short circuit for the
sake of covering the as less space as possible.
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Making PCB using Milling Machine

 Now you are all done with your schematic diagram and PCB layout design.
 There are two ways to create PCB i.e additive method and subtractive method.
In additive method we add copper on the predefined trances on the board and
in substractive method we remove unwanted copper from the copper clad,
leaving behind the copper traces that electrically connect different components.
 In milling machine we will use substractive method where we use copper placed
on the predefined lines and will remove unwanted copper.
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Milling Process

 Milling process will take no more than 30 minutes however it depends on the thickness of the
bit and the size of the PCB and the number components and their alignment it would carry.
 PCB milling is the method which involves removing the unwanted copper from the board to
create paths, and signal traces according to the layout design.
 It is totally non chemical process which can be achieved in lab environment and involves no
hazardous chemical and gives a quick turnaround if you intend to make number of PCBs.
 The quality of PCB depends on the milling accuracy and sharpness of the milling bits you
use for milling.
 The rotational speeds of milling bits have little or no effect in the quality and precision of PCB.
 You need to practice this process of making PCB using milling machine if you are using
milling machine for the first time.
 You will be able to make high quality product with greater precision if you take few
precautions prior to making PCB.
 Software used for PCB milling is provided by milling machine manufacturer.
 Software can be divided into two categories i.e. Raster and Vector.
 Software that utilizes raster calculations comes with lower processing resolution than vector
based category because it is dependent on the raster information.
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Mechanism
 PCB milling machine makes use of advanced CNC milling technology.
 The milling machine controller is controlled by software that receives commands
and machine control information through serial and parallel port.
 The controller is able to monitor the positioning features that are capable of
moving the milling head and control spindle speed.
 Spindle speed depends on the type of system you use and it ranges from 30,000
rpm to 100,000 rpm.
 Higher spindle speed comes with higher accuracy and better precision.
 The whole positioning system consists of stepper motor for x and y axis and
pneumatic piston for z axis and simple DC motor is used to control the spindle
speed.
 In order to control higher speed, RF spindle motor control is used.
 More advanced drive systems come with monitored stepper motor that provides
greater control during milling and drilling process.
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Other Processes

 After completing the milling process, you can solder required components into
the board based on your needs and requirements.
 There are two ways to place and solder the components on the board. One is
through hole process and other is surface mount process.
 Through hole process involves inserting the leads into the PCB hole and then
connect to the pins of right components.
 This process becomes obsolete as it is an older process and occupies more
space.
 Surface mount technology is an advanced method in which components are
mount on the board surface and then soldered to the right components.
 This process occupies lesser space than through hole process and is an ideal
choice for most of the professionals.
 Be sure to take appropriate measure before soldering the components. The
solder you use for soldering the components mostly consists of lead that is
considered as a toxic material.
 And the fumes created by the the soldering can be hazardous to health.
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 It is better to clean and extract the fumes before you discharge them into the
environment.
 You must take safety measures before you start milling the board. You should
wear safety goggles, use the drill bit carefully and put your hand away from the
board when spindle is active.

Advantages
 PCB milling process comes with a lot of benefits because it involves no
hazardous chemical and is an ideal choice for mass production.
 Best part is that CNC milling can be used for multiple purpose i.e milling, drilling
and cutting.
 You can change the bits based on your needs and requirements.
 Some PCB boards that are easy to create using PCB milling process are very
difficult to create using wet etching process that also involves manual drilling
afterwards which costs lot more than regular milling process.

 1. It does not require the hazardous chemicals

 2. PCBs can be produced within the lab

 3. PCB fabrication is instant

 4. Tracks and land patterns can be produced very accurately, such as for
microwave and RF applications

 5. A single machine can be used for milling, drilling, and cutting the PCB

 6. The Gerber files can be directly linked to the CNC machine

 7.Suitable for environments where PCBs are sufficient to be used without solder
masking, through-hole plated vias and pads, and surface finishing

This method also has some disadvantages:

1. It is not suitable for large-scale production

2. PCB cost is high due to tools breakage

3. Spindle cooling is required for high-speed spindle machines

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4. Minimum PCB tracks width, clearance, via size, annular ring, and minimum hole
size are the design side constraints

5. Separate machining setup is required for vias and through-hole pads insertion

6. Any misalignment or deviation in drilling or milling tool causes inaccuracies in

the fabricated PCBs. The PCB object’s position precision is highly dependent on the
machine spindle and tool.

In conclusion, the large quantity of precision PCBs production best suits the wet or
etching method, and minimal scale prototype testing PCBs suit using the CNC
fabrication method.

Alternative Methods

 Laser etching is a great alternative to both chemical etching and milling process.
 This process is an ideal choice for most of the applications because it involves no direct
contact with the board and it removes the material without physically touching it.
 When it comes to high precision and greater accuracy, laser etching process is preferable
and is mostly used for advanced microwave and RF designs.
 This process involves low power consumption, delivers high accuracy, doesn’t make use of
lubricants and abrasive material and pertains to low wear and tear and needs less
maintenance.
 However, this process also comes with some limitations and is expensive as compared to
other processes.