PRODUCTION OF PCB AND MACHINE TESTING

PREPARED BY : PALLAVI SHARMA

(16BEC040)
 INTRODUCTION
Printed circuit boards (PCBs) are the boards that are used as the base in most electronics – both as a physical
support piece and as the wiring area for the surface-mounted and socketed components.

Although PCBs are most often associated with computers, they can be found in many other electronic devices,
such as TVs, Radios, Digital cameras and Cell phones. In addition to their use in consumer electronics and
computers, different types of PCBs are used in a variety of other fields, including:
 Medical devices.
 Industrial machinery.
 Lighting.
 Automotive and aerospace industries.
Since their invention at the turn of the century and their patenting by Paul Eisler in 1943, printed circuit boards
have evolved and advanced far beyond their original functionalities.

PCBs today are tiny, multilayered, complex systems that hardly resemble their earliest ancestors. They're also
produced at a much higher and more efficient rate than ever before thanks to sophisticated design software and
manufacturing processes. Even 10 years ago, microvias, HDI and FPGAs were only seen in the most expensive
designs, yet are now readily available to designers worldwide.

As technology and consumer demand grows and develops, however, so must PCBs. As the basis of all electronic
devices, PCBs feel intense pressure for development and growth. With consumers pushing for slimmer and faster
devices, and with industries seeking improved functionality, the PCB must continue developing into the future.
 BASICS OF PRINTED CIRCUITS BOARDS (PCBs)

 COMPOSITION

In PCB there are alternating layers of different materials which are laminated together with heat and adhesive
such that the result is a single object.

There are four main parts to a PCB:

1. Substrate(FR4)
2. Copper
3. Soldermask
4. silkscreen
1. Substrate(FR4)

The first, and most important, is the substrate, usually made of fiberglass. Fiberglass is used because it provides
a core strength to the PCB and helps resist breakage. Think of the substrate as the PCB’s “skeleton”

2. Copper Layer

Depending on the board type, this layer can either be copper foil or a full-on copper coating. Regardless of
which approach is used, the point of the copper is still the same — to carry electrical signals to and from the
PCB, much like your nervous system carries signals between your brain and your muscles.
3. Solder Mask

The third piece of the PCB is the solder mask, which is a layer of polymer that helps protect the copper so that it
doesn’t short-circuit from coming into contact with the environment. In this way, the solder mask acts as the PCB’s
“skin”.

4. Silkscreen:

The final part of the circuit board is the silkscreen. The silkscreen is usually on the component side of the board
used to show part numbers, logos, symbols switch settings, component reference and test points. The silkscreen can
also be known as legend or nomenclature.

Silkscreen is most commonly white.

 TYPES OF PRINTED CIRCUIT BOARDS (PCB)

There are several overall types of PCB boards each with their own particular manufacturing specifications,
material types and usages:
o Single-layer PCBs
o Double-layer PCBs
o Multi-layer PCBs
o Rigid PCBs
o Flexible PCBs
o Rigid-Flex PCBs
o High-frequency PCBs
o Aluminum-backed PCB
1. Single-layer PCBs

A single-layer or single-sided PCB is one that is made out of a single layer of base material or substrate. Since
single-layer/single-sided PCBs only have their various circuits and components soldered onto one side, they are
easy to design and manufacture.

2. Double-layer PCBs

Double-layer or double-sided PCBs have a base material with a thin layer of conductive metal, like copper, applied
to both sides of the board. Holes drilled through the board allow circuits on one side of the board to connect to
circuits on the other.
3. Multi-layer PCBs

Multi-layer PCBs consist of a series of three or more double-layered PCBs. These boards are then secured together
with a specialized glue and sandwiched between pieces of insulation to ensure that excess heat doesn't melt any of
the components.

4. Rigid PCBs

Rigid PCBs are printed circuit boards that are made out of a solid substrate material that prevents the board from
twisting. Possibly the most common example of a rigid PCB is a computer motherboard.
Rigid PCBs make up perhaps the largest number of PCBs manufactured.
5. Flexible PCBs

Unlike rigid PCBs, which use unmoving materials such as fiberglass, flexible PCBs are made of materials that can
flex and move, such as plastic. Like rigid PCBs, flexible PCBs come in single, double or multilayer formats.

6. Flex-rigid PCBs

Flex-rigid PCBs combine the best of both worlds when it comes to the two most important overarching types of
PCB boards. Flex-rigid boards consist of multiple layers of flexible PCBs attached to a number of rigid PCB layers.
 PCB MANUFACTURING PROCESS
Printed Circuit Boards (PCBs) form the backbone of all major electronics. Producing a PCB is a complex process that
involves many steps.

 PCB Design and Layout

Circuit boards should be rigorously compatible with, a PCB layout created by the designer using PCB design
software. Commonly-used PCB design software includes Altium Designer, OrCAD, Pads, KiCad, Eagle etc.

 From File to Film

PCB printing begins after designers output the PCB schematic files and manufacturers conduct a DFM check.
Manufacturers use a special printer called a plotter, which makes photo films of the PCBs, to print circuit boards.
Manufacturers will use the films to image the PCBs.
 Printing the Inner layers

The creation of films in previous step aims to map out a figure of copper path. Now it's time to print the figure on the film
onto a copper foil. This step in PCB manufacturing prepares to make actual PCB.

 Removing the Unwanted Copper

With the photo resist removed and the hardened resist covering the copper we wish to keep, the board proceeds to the
next stage: unwanted copper removal. The copper solvent solution bath removes all of the exposed copper .

 Layer Alignment and Optical Inspection

With all the layers clean and ready, the layers require alignment punches to ensure they all line up. The registration holes
align the inner layers to the outer ones.
 Layer-up and Bond

In this stage, the circuit board takes shape. All the separate layers await their union. With the layers ready and confirmed, they
simply need to fuse together. Outer layers must join with the substrate. The process happens in two steps: layer-up and bonding.

 Drill

Finally, holes are bored into the stack board. All components slated to come later, such as copper-linking via holes and leaded
aspects, rely on the exactness of precision drill holes. The holes are drilled to a hairs-width - the drill achieves 100 microns in
diameter, while hair averages at 150 microns.

 Plating and Copper Deposition

After drilling, the panel moves onto plating. The process fuses the different layers together using chemical deposition. After a
thorough cleaning, the panel undergoes a series of chemical baths.
 Outer Layer Imaging

In Step 3, we applied photo resist to the panel. In this step, we do it again - except this time, we image the outer
layers of the panel with PCB design. We begin with the layers in a sterile room to prevent any contaminants from
sticking to the layer surface, then apply a layer of photo resist to the panel.

 Plating

We return to the plating room. As we did in Step 8, we electroplate the panel with a thin layer of copper. The exposed
sections of the panel from the outer layer photo resist stage receive the copper electro-plating. Following the initial
copper plating baths, the panel usually receives tin plating, which permits the removal of all the copper left on the
board slated for removal.

 Final Etching

The tin protects the desired copper during this stage. The unwanted exposed copper and copper beneath the
remaining resist layer undergo removal.
 Solder Mask Application

Before the solder mask is applied to both sides of the board, the panels are cleaned and covered with an epoxy solder
mask ink

 Silkscreen

The nearly completed board receives ink-jet writing on its surface used
to indicate all vital information pertaining to the PCB.

 Profiling and V-Scoring

As a final precaution, a technician performs electrical tests on the PCB. The automated procedure confirms the
functionality of the PCB and its conformity to the original design. Now we've come to the last step: cutting. Different
boards are cut from the original panel
 PCB’s IN MEDICAL TECHNOLOGY

Electronics products are now denser and consume less power than previous generations, making it possible to test
new and exciting medical technology.
Most medical devices use a high-density PCB, which is used to create the smallest and densest design possible.
This helps to alleviate some of the unique constraints involved with developing devices for the medical field due to
the necessity of small size and light weight.

PCBs have found their way into everything from small devices,
such as pacemakers, to much larger devices like X-ray
equipment or CAT scan machines.
 NIBP MACHINE
The Columbus Instruments' Non-Invasive Blood Pressure (NIBP) Monitor can monitor systolic, diastolic, mean blood
pressure, as well as heart rate with 7% accuracy in one to eight rats or mice.
The NIBP is fully automatic and results are presented on the screen and may be printed and/or saved to a file because
the numerical values pressure in mmHg, as well as graphical pictures of the signal from the pulsation sensor and a graph
of ascending and descending pressure within the occlusion sensor. After completion of the measurement, the user has
the option to review the results by displaying signals from both cuffs and make a decision to accept or reject the
measurement.

 Components used in the making of NIBP Capillary Tube

1. NIBP transparent tube
2. Blue capillary material to be inserted and steel wire
3. Sand paper
4. NIBP capillary
5. Tweezers
 STEPS FOR MAKING OF CAPPILARY TUBE
 STEP-1
•The width of steel wire should be 0.34mm.
•The steel wire is to be cut 30 to 35mm in length with a cutter.
•The blue material of capillary placed in the wire has to be cut out
-t with the help of a stripper into the following dimensions:-
:- from 2.5 to 3.5mm
 STEP -2
•Smoothening and polishing of the blue cut out capillary
material by gently rubbing it from both ends by sand paper into appropriate dimensions : I.e. from 2.5 to 3.5mm
 STEP -3
•The steel wire should be able to move up and down within the capillary to ensure that there are no blockages in
the break air passage (hole).
 STEP -4
•The capillary along with the steel wire is to be placed inside the transparent tube.
• For this thin side of capillary (2.5mm) goes first inside the tube

 STEP -5
•The blue capillary should go inside the transparent tube up to
20 to 25mm by pushing with the help of a tweezers

 STEP -6
•After insertion move the steel wire up and down 3 to 4 times inside the transparent tube.
•Finally, gently pull out the steel wire in such a way that the capillary remains inside the tube.
 TESTING
 STEP-1
The following components will be assembled systematically:
• Simulator: to check the pressure in mmHg.
• Interface Jig : to connect the computer with the card( provides interface)
• NIBP Card: to provide pressure.
• NIBP Monitor: gives supply signal to the card.
• Computer screen to observe output waveforms.
• Pump provides the air/pressure
 STEP -2
 Check the pressure up to 200 mm Hg within 42 to 45 seconds on the computer screen.5mm
 STEP -3
 If capillary is distortion is observed the NIBP rejected.
 STEP-4
 If no or very little distortion is observed then the NIBP capillary is passed.
 FUTURE SCOPE
The PCB industry is already a fast-growing industry, with some studies estimating that the market will grow
from $63.5 billion in 2016 to $73.8 billion in 2021. However, the fastest-growing segment of the PCB
industry is flexible PCBs - projected to grow to $15.2 billion by 2020 and $27 billion by 2022.

here's also plenty of room to grow in the manufacturing process itself as increased PCB complexity
introduces new challenges for manufacturing companies. That's why most predictions for the printed circuit
board's future focus strongly on the following areas.

All of this implies that those who are thinking about which career path to take should seriously consider
becoming PCB designers!
 THANK YOU
!