The process of PCB fabrication is impressive, and even those familiar with PCB design might not know all the ins and outs of how PCBs are made. Learn more about the different PCB fabrication techniques that make your design go from the virtual image on your computer screen to the tangible, green board in your toaster.

The Basics

Before diving into PCB fabrication, it’s important to know what makes up a PCB. Often, people will describe PCBs as a layered cake. The most basic PCB designs have four layers: the substrate (base), copper, solder mask, and silkscreen. These layers all work together and must be in total alignment for the final product to work.

Once you’ve designed a PCB and sent your PCB design off to the manufacturer, what will they do with it? For starters, they use your PCB design as the blueprint for the entire process.

Through-Hole Method

One of the earliest forms of PCB fabrication was the through-hole method. This tried-and-true method is quickly being replaced by a more modern PCB fabrication, known as surface mount technology (SMT). While each has its advantages and disadvantages, SMT PCB manufacturers seem to be able to produce smaller and cheaper PCB boards.

We’ll take a look at the intricate work that goes into a through-hole PCB design first. The most significant difference of the through-hole method is that manufacturers drill a hole into the board so that factory workers can double-check that each layer is aligned before moving onto the next step. With the through-hole method, manufacturers will print your PCB design onto special laminate paper. The manufacturers can attach a thin sheet of copper once the design is captured onto this special paper. This will be the basis of your substrate, or the base of the PCB.

Creating Layers

The next step is to start working on the copper that will form the layers of your PCB. This process is a bit similar to how photographs are developed – to the point that at-home PCB makers will use the same processing chemicals. Essentially, the special laminate paper is covered with photo-reactive chemicals, and when a UV light passes over it, it hardens the desired areas. This shows manufacturers which parts, based on your design, should be kept for the final PCB board and which bits of copper should be chipped away.

When the chemicals dry and harden, the board is washed in an alkaline solution and is ready to be inspected. If the board is good to go, a technician uses a powerful chemical to remove unnecessary copper, leaving behind only the copper needed per your PCB design.

Next, the copper layers are laminated together. Technicians must keep a keen eye for detail and always watch that each layer is perfectly aligned with the last. The result is a beautiful, half-finished board.

Factories can use an x-ray machine to uncover where the holes are meant to be drilled and then use a high-powered drill for precise execution. The board is finally plated, and the layers are fused with a series of chemicals. There is one last etching that occurs before the solder mask is attached. This etching ensures that your PCB has the right connections to make your creation function.

Surface Mount Technology

Surface mount technology (SMT) has become more commonplace in the PCB fabrication process because it allows for easier mass production. With an SMT outfit, the PCB fabrication process is more automated and thus less prone to human error. SMT-designed PCBs also do not have the same hole that is prominent in the through-hole method. Here’s a brief glimpse into how these PCBs are produced.

Simple As a Stencil

By using high-powered computers and technology, machinery takes your PCB design and creates a stencil. The stencil contains all the information the automated process will need to finish up your design. The stencil also allows machines to trace solder paste onto the board only in the designated areas.

The board is now ready to run through a pick-and-place machine, which takes the guesswork and error out of the PCB design process. The pick and place machine holds various components in their reels and reads the solder paste to place the proper components onto the board as directed by the PCB’s design. The solder paste will also hold everything in place so that components cannot be knocked off-kilter, thus resulting in a faulty product.

Once this process finishes, the PCB is heated and melts the soldering paste so that the layers meld together. The PCB is then ready for a clean-up, to ensure there is no residual solder paste on the board. At last, the board will receive an inspection of any potential defects.

Advantages of Surface Mount Technology

As you can see, SMT is a much more straightforward and more automated process. Its simplicity is what makes it best for the mass production of PCBs. Once a stencil is created for a design, you can print countless boards. Since the process relies on computers and machines rather than technicians, it’s also less vulnerable to human error. If there’s a mistake with a PCB board, it’s likely because the pick and place machine needs some reconfiguration.

Another big advantage of SMT fabrication is that they tend to allow for higher density component placement while still maintaining smaller boards. Since the board is smaller, the connections have a shorter distance to travel for better power.

The most significant disadvantage of the stencil-based process is that it makes it more challenging to produce prototypes quickly. This system works best if the same stencil is being used repeatedly, rather than creating one stencil that will change.

However, given the automation of the SMT process, it’s no wonder that the SMT fabrication method has gained greater momentum in the PCB world than the through-hole. Whichever route you go, make sure you’re aware of the PCB fabrication process that your manufacturer uses. In today’s world of making everything faster and smaller, you’ll want to make a decision that gives you the best return on investment.

Designing any sort of device that requires a PCB with SMT means:

• The device can provide many more functions. SMT drops the total weight of a PCB. It is not as labor-intensive and has little need for drilling and soldering that can cause malfunctions. Smaller devices that work better and cost less are one direct benefit.
• Automation is easier. Using SMT means leveraging mass production of PCBs, and yet also enjoying higher quality and performance.
• Reduced costs and production times. Eliminating drilling and the time it takes is another key benefit of SMT.

Unfortunately, not all producers of PCBs can extend SMT to customers utilizing their designing, manufacturing, and assembly processes.

Advanced Circuits Has Surface-Mount Technology

At Advanced Circuits, buyers are able to enjoy the benefits that come from SMT in addition to an astonishing range of free tools and resources that can make even more of surface-mount technology and PCBs.

We are a top name in PCB and prototyping, offering all clients an array of tools essential to top-notch SMT production. While we might offer an umbrella statement or two about SMT, we feel it better to explain how we make it available to buyers. For example, we have SMT Solder Paste Stencils available as part of our options for those who need a one-off or “by-hand” SMT manufacturing and design option.

If you are looking for something more, we also have advanced design tools that enable easy integration of SMT features and designs.

Resources Chosen for SMT

Those familiar with the PCB design process are already well-versed in the issue of Gerber file designs and other PCB design programs. Often, this may mean that the advanced technology is used, but the design left untested. This is especially the case when producers utilize the common no-touch approach. Typical to the outsourced and brokered services, the clients’ designs are accepted and run, without any sort of engineering review. When one is mandatory, it means that the file is reviewed long before fabrication begins and is intended to identify design flaws or potential issues that might lead to delays or wasted resources.

Advance Circuits Offers Resources for SMT Designs and Projects

FreeDFM– This is software designed to perform a complimentary and rapid design assessment. The software is easy to use and guarantees that key data is available; it will even make corrections to some common design issues. It generates a full report and promises great outcomes. It does not matter if a PCB features traditional drilling or SMT; it will emerge an improved and error-free design once reviewed through this software. Those who utilize the program also enjoy a discount if the design is submitted through the software. It can do a full conversion to Gerber format in only a few minutes, provide a quote, extend the discount code, and feature a link to the PDF of the full report.

PCB Artist – Clients enjoy 100% free access to this PCB design software, as well as accessing the unrestricted copy of the software. With the ability to manage up to 28 layers and featuring a library of over 500,000 parts, an auto-router function, multi-page schematics, and surface-mount technology features, it can meet even the most advanced demands. It is recognized as an industry-best PCB design tool.

At Advanced Circuits, we also provide standard and traditional client services to clients, too. What does that mean? All SMT orders have a full CAM engineer review. This guarantees that your design, even if extremely complex, gets a full and expert evaluation and any adjustments needed.

On top of all of this, we also have further benefits for those who decide to team up with our firm for their PCB needs (whether or not SMT is part of the overall design). Our additional benefits include:

• No minimum orders. There are no minimum lot requirements, meaning that clients are not forced to invest in huge orders with more PCBs than might be needed. Prototyping is an option – even with SMT features.
• 24-hour support. Customer service around-the-clock features live tech support that allows design teams to speak directly with a CAM engineer at any hour of the day or night.
• Best shipping record. Advanced Circuits has the BEST ON-TIME SHIPPING RECORD in the industry, and we’re now shipping 50% of orders early! In fact, we say we “put our money where our mouth is . . . and we ship Standard Spec orders on time or they’re FREE!”
• No tooling charges. When an order features Standard Specifications, we are glad to waive tooling charges and always cancel such fees on reorders of Standard Spec as Custom Spec items.
• Not a broker. We never sub out our work but instead count on our top-of-the-line, 62,000-square-foot facility that guarantees the kinds of quality and speed most want but cannot always receive.
• Dedicated client pages. Here you can look through past orders, see the specs and details, look at quotes from other jobs, and even review hold notices, test certifications, and a long list of other helpful reports.
• We are stable. With more than two decades of work in this industry, a healthy bottom line, and many dedicated clients, we are among the most stable of providers, guaranteed to be around for years after your projects are completed.

We also have an enormous and fully-capable plant that incorporates design, production, assembly, and shipping services all in one space, emphasizing efficiency at every step of the way.

Using SMT makes perfect sense, and yet it can often come at a premium price with lots of costly and risky production requirements or gaps in service. It is imperative that producers have a chance to submit designs for expert review, get feedback and corrections, and get what is needed. Why operate within the “no-touch” system when you can get prototypes, reviews, and free tools for projects of any complexity from Advanced Circuits?

• Offering many more capabilities – The weight of a PCB that uses surface-mount technology, instead of labor-intensive and error-prone drilling and soldering means that the capabilities are improved. The era of shrinking devices means that the capability to create PCBs smaller and lighter than ever is a major advantage.
• Saving time and money – The time and complexity of drilling is eliminated when surface mounting can be used instead.
• Using automation – It makes sense to leverage the ability to mass-produce PCBs that retain performance and quality, and surface mount technology is one sure-fire way to do so.

Not all manufacturers have the ability to offer their clients surface mount technology in their design, manufacturing and assembly processes. However, Advanced Circuits has made certain that buyers can utilize our long list of free resources and amazing tools to put surface mount technology to the greatest use possible.

As a leading name in prototyping and PCB production, we provide buyers with a diversity of resources for all SMT production. We have SMT Solder Paste Stencils available as part of a NEW complete prototyping stencil kit for those who want to do one-off or “by hand” SMT manufacturing and design. Yet, we also have our remarkably advanced design tools that allow for integration of SMT designs.

Surface Mount Technology-Friendly Resources Enable Production

To begin, when a client uses existing Gerber-file designs, or other PCB design programs, the outcome of the production is never left “up in the air” as it might be when a “no-touch” approach is used. This is a serious problem with outsourced or brokered designs in which the schematics are taken and run. Instead, any orders received undergo a mandatory engineering file review before the fabrication process is started. This identifies unusual or even typical glitches in the designs and ensures that a client’s time and money will never be wasted by design flaws or manufacturing flaws or avoidable errors. This also ensures production schedules remain on track.

Other Advanced Circuits surface mount technology-friendly tools include the following free resources:

PCB Artist – Customers of all skill levels appreciate the 100% free access we provide to this innovative PCB design software. Provided as an unrestricted copy of the software, it is capable of up to 28 layers and includes more than 500k parts, a controlled auto-router function, multi-page schematics, and surface mount technology features. Easy to use and 100% free, it is also noted throughout the industry as the very best PCB design tool.

FreeDFM– This software enables clients to run a free and fast design assessment. It works easily and simply and ensures files feature all essential data, automatically corrects some issues, and provides an easy to read and use report. Whether a design features surface mount technology or relies on drilling, it will be as error and glitch-free as possible after running through this feature. Using it also comes with a discount on the work if the designs are submitted through the software. This software converts to Gerber format, takes only minutes, and issues a quote, discount code and link to the PDF of the results.

We proudly make all of our standard and traditional client services readily available to custom clients, too. That means any SMT order will also get that CAM engineer review that ensures that a design of even great complexity will be evaluated and adjusted.

And while this alone is enough for most clients to feel confident and comfortable with an order through Advanced Circuits, there are other services and benefits to partnering with us for PCBs with or without SMT technology. They include:

• Not a broker – We never sub out our work but instead count on our top of the line, 62k square foot facility and team that guarantee the kinds of quality and speed most want but cannot always receive.
• No minimum orders – There are no minimum lot requirements, meaning that clients are not forced to invest in huge orders with more PCBs than might be needed. Prototyping is an option – even with SMT features.
• 24-hour support – Customer service around the clock: this features live tech support that allows design teams to speak directly with a CAM engineer at any hour of the day or night.
• No tooling charges – When an order features Standard Specifications, we are glad to waive tooling charges and always cancel such fees on reorders of Standard Spec as Custom Spec items.
• Best shipping record – Advanced Circuits has the BEST ON-TIME SHIPPING RECORD in the industry, and is now shipping 50% of orders early! In fact, we say we “put our money where our mouth is . . . and we ship Standard Spec orders on time or they’re FREE!”

We also point out our decades of stability as a wise reason to work with us. After all, with more than 25 years in the field, and a tremendously healthy bottom line, we are among the most stable providers. We have a vast and fully-capable plant offering design, production, assembly and shipping services, and we emphasize efficiency at all levels.

As a client, you also enjoy the use of a personalized client page. Here you can look through past orders, see the specs and details, look at quotes from other jobs, and even review hold notices, test certifications, and a long list of other helpful reports.

One-Offs or Thousands of PCBs: Advanced Circuits Delivers Unrivaled Quality

The use of such a streamlined process as surface mount technology should never come with punitive pricing and complex or risky production requirements. Clients should be able to send in designs and have them expertly reviewed and corrected, rather than crossing their fingers with a “no-touch” approach to manufacturing. Advanced Circuits takes prototypes and one-offs as seriously as we do batches of thousands of PCBs. Clients can feel confident that basic to complex jobs will be done quickly, efficiently and as fully-supported as needed.

However, the creation of PCBs with SMT manufacturing is quite complex and demands the use of advanced tools and technologies. DFM, or design for manufacturing, as an example, is the “coupled” process that integrates the basics of the PCB and takes into consideration the SMT manufacturing phases as well as the functionality of those SMT processes.

Will the design work as is or will there be a reworking of the PCB necessary? This is one of the major questions asked at the preliminary or prototyping phase, and often the SMT manufacturing component takes the back seat. However, as a design makes its way through the approval processes, SMT manufacturing has to enter the equation. Not only because it is essential to the actual function of the end product, but because it is such a cost-effective measure when hole-drilling can be eliminated.

The benefits of opting for SMT manufacturing include:

• Cost-cutting – The time and complexity of drilling is eliminated when surface mounting can be used instead
• Capabilities increased – The weight of a PCB that uses SMT manufacturing rather than drilling and soldering pastes means that the capabilities are improved, too. The era of the smaller and smaller device means that this design capability can open many previously closed doors.
• Automation – It makes sense to leverage the ability to mass-produce PCBs that retain performance and quality, and SMT manufacturing is a key approach to consistency when producing in mass quantities.

Of course, when considering SMT manufacturing, it also means being able to simultaneously ensure that the design is easily produced and effective. This is where Advanced Circuits can step in and make all of the difference. We have a nearly flawless system that alleviates design flaws in the pre-production process, and helps to cut down on rework that is often the bane of SMT manufacturing.

PCB and SMT Design Resources Bring Optimal Outcomes

Advanced Circuits is a well-known name in the PCB and Prototype Assembly industries. We can handle PCB manufacturing (fabrication) and assembly, including SMT designs.

We are a full-service provider with more than two decades in the field, and give clients exclusive services that support a project of any complexity or simplicity – whether a one-off prototype or a design with SMT and mass production requirements. The resources we make available for them include:

PCB Artist – Customers of all design levels love the free access we provide to this innovative PCB design software. Unrestricted, it is capable of up to 28 layers and includes more than 500k parts, a controlled auto-router function, multi-page schematics, and more. Easy to use and 100% free, it is also noted throughout the industry as the very best PCB design tool.

FreeDFM– This software enables clients to run a free and fast design assessment. It works easily and simply by using uploaded design files, then the program ensures files feature all essential data, automatically corrects some issues, plus provides an easy to read and use report. Using it also comes with a discount on the work if the designs are submitted through the software. This software uses Gerber format, but it takes only minutes, then a quote, discount code and link to the PDF of the results will appear.

All orders undergo a mandatory engineering file review before the fabrication process is initiated. This guarantees that glitches part of the typical “no-touch” approach will not occur, and that time and money will never be wasted by design flaws or manufacturing problems (i.e. rework issues) that could have been avoided.

End Reworking, Delays, and Clunky Design

Worried that learning the free software will take too long or ask too much before showing you how to integrate SMT into your designs? No need to worry, because the PCB Artist software we offer comes with printable tutorials and video options that walk even a beginner through the complex process of PCB design and manufacturing. And when the files are ready, the PCBs can be ordered directly through the software.

And, while the free PCB design resources made available on our site are enough to make us a premier and preferred provider, there are many other reasons to buy PCBs that incorporate SMT manufacturing from Advanced Circuits, including:

• No minimum orders – There are no minimum lot requirements, meaning that clients are not forced to invest in huge orders with more PCBs than might be needed. Prototyping is an option – even with SMT features.
• 24-hour support – Around the clock customer service features live tech support that allows design teams to speak directly with a CAM engineer at any hour of the day or night.
• No tooling charges – When an order features Standard Specifications, we are glad to waive tooling charges and always cancel such fees on reorders of Standard Spec as Custom Spec items.
• Not a broker – We never sub out our work bt instead count on our top of the line, 62k square foot facility and that guarantee the kinds of quality and speed most want but cannot always receive.
• Best shipping record – Advanced Circuits has the BEST ON-TIME SHIPPING RECORD in the industry, and is now shipping 50% of orders early! In fact, we say we “put our money where our mouth is . . . and we ship Standard Spec orders on time or they’re FREE!”

With so many reasons to choose Advanced Circuits, and with all of our free PCB design tools and resources available, it makes good sense to get in touch with us today. Our instant quotes and easy order tracking mean that a manufacturing or electronics firm of any size can obtain top quality PCBs designed flawlessly and to precise specifications. We also make SMT Solder Paste Stencils available as part of a NEW complete prototyping stencil kit for those who want to do one-off or “by hand” SMT manufacturing and design.

Ready to Place Your PCB Order at Advanced Circuits?

When you are ready to place your order with Advanced Circuits you have different options for a quote based on your preference. When you register for an account with Advanced Circuits you can get an instant quote online, use the FreeDFM file check system to get a detailed quote, or request a traditional quote by email. Contact the experts at Advanced Circuits today for more information.