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INTRODUCTION

Electronic devices saturate the modern world. Whether it is a device that silently
monitors vitals or a smartphone with an endless stream of notifications, all contain a
PCB circuit board at the heart of their design. Over the years, printed circuit board
manufacturing has continued to grow in order to keep up with the increasing demands of
newer, faster, and more complex electronic circuitry. Discussions on the processes
involved in devising and designing a PCB circuit board could fill a library, but here we
will provide a surface-level introduction of the basics.

A printed circuit board is a rigid structure that contains electrical circuitry made up of
embedded metal surfaces called traces and larger areas of metal called planes.
Components are soldered to the board onto metal pads, which are connected to the board
circuitry. This allows components to be interconnected. A board can be composed of
one, two, or multiple layers of circuitry.

Circuit boards are built with a dielectric core material with poor electrical conducting
properties to ensure pure circuitry transmission and interspaced with extra layers of
metal and dielectric as needed. The standard dielectric material used for circuit boards is
a flame-resistant composite of woven fiberglass cloth and epoxy resin, known as FR-4,
while the metal traces and planes for the circuitry are usually composed of copper
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TYPES OF PRINTED CIRCIT BOARDS

In general, boards can be categorized into one of three categories: rigid, flex, or metal-
core boards.

Rigid boards are often the vast majority of boards a designer will encounter, where the
layout of the board is contained within a rigid substrate created from a high heat and
pressure lamination process. The common material for these boards is FR-4, but
depending on the particular needs of the design, this can be modified to emphasize or
otherwise improve certain characteristics of the board.
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FLEXIBLE BOARDS
These are designed using materials that are significantly less rigid than
traditional printed circuit boards (PCBs), enabling them to bend, twist, and conform to
complex three-dimensional shapes. Typically made from polyimide or similar high-
performance plastic films, these flexible boards are thin, lightweight, and durable,
resembling the feel and flexibility of photographic film. Unlike rigid boards, which
maintain a fixed shape, flexible PCBs can undergo repeated mechanical deformation
without breaking, making them ideal for dynamic or compact applications.
The reduced thickness and pliability of flexible boards not only allow for innovative
product designs but also enable the integration of electronics into environments
previously considered impractical. Already in use in industries such as aerospace,
automotive, and medical devices, flexible PCBs are rapidly gaining traction in consumer
electronics, especially in the field of wearable technology. Devices like smartwatches,
fitness bands, and even smart textiles benefit from the adaptability and space efficiency
provided by flexible circuits.
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Metal-core printed circuit boards (MCPCBs)

These are a specialized subset of rigid PCBs that incorporate a

metallic base layer—typically aluminum, copper, or a combination thereof—to
significantly enhance thermal conductivity. Unlike standard fiberglass-based boards
(FR-4), which can struggle to manage excess heat, MCPCBs are engineered to
efficiently dissipate heat away from critical components. This capability makes
them especially suitable for high-power and high-current applications, such as
LED lighting systems, automotive electronics, and power converters, where thermal
management is vital for maintaining performance and longevity.

The metal core acts as a heat sink, drawing thermal energy away from heat-
generating components and spreading it uniformly across the board. This reduces
the likelihood of thermal hotspots, which can degrade sensitive circuitry or lead to
outright failure if left unchecked. As such, MCPCBs help in improving reliability,
extending product lifespan, and reducing the need for external cooling mechanisms.
On a broader scale, wherever controlled electromagnetism is involved—whether
in transmitting signals, processing data, or converting power—PCBs form the
foundational infrastructure that supports and connects electronic components.
They provide not only mechanical support but also electrical routing, grounding,
and insulation needed for devices to operate safely and efficiently.

However, circuit boards don’t simply materialize out of thin air.The process
requires collaboration between electrical engineers, materials scientists, and
manufacturing specialists to ensure that the board meets both functional and
physical performance standards.
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USING PCB DESIGN TOOLS

 Stencils
Stencils are stainless foils that are used to apply the solder paste onto the board.
A solder mask is used to prevent any excess solder paste deposition on selected
areas.

 Soldering Machine
This is used to attach and fix all the electrical components onto the Printed
Wiring Board. Usually, the soldering machine comprises a lead or tin solder.

 Excellon File
This is also known as drill file. It is a file format that is used to govern the
sizes and locations of finished holes on the printed circuit board. Excellon files
usually contain information about drill tool number, hole size and quantity, and
whether or not the holes are plated.

 Nipper
 Wire Nipper
 Flat Nose Plyer
 Side Cutter
 Diamond Cutter
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CHEMICALS USED DURING THE PREPARATIONS OF PCBs

1. Sodium Bicarbonate

2. Ferric Chloride

3. Conc. Sodium Hydroxide

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SOFTWARE USED

 EAGLE
EAGLE is electronic design automation (EDA) software that lets printed circuit
board (PCB) designers seamlessly connect schematic diagrams, component
placement, PCB routing and comprehensive library content.

MY PCB PROJECT
In my PCB Design and Fabrication Skill Course I designed an LDR Sensor Module
using the various tools of Eagle Software. Its user-friendly interface helped to build my
sensor module as we thought.
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Just designing is not enough, the tracks of the sheet on which we are designing should
reach to every component we used in our module and every path to the component should
be unique and they must not overlap with each other.

HOW PCB IS FABRICATED

 Clean the copper using thinner.

 Place the thin film.

 For giving temp & pressure to film we are using iron, so that film sticks

with copper board.

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 I had printed the bottom part of pcb which I designed in Eagle.

 Put oil on film placed on copper then put that printed papers and kept the

whole copper board in between 2 glass slabs.

 Kept it under sunlight for 2minutes.

 Take it out from slab n remove that printed paper, and wipe the oil.

 In a small tub take sodium bicarbonate, dip the copper, then we'll be able to see

the tracks clearly and then wash it with Water.

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 Again, put that copper sheet in Ferric Chloride solution till 15min, then wash
it with water.
 Then again dip the sheet in the conc Sodium Hydroxide solution then we'll
observe that the excessive film comes out of it and we get a clear trace of our
circuit on the copper sheet. This whole process is called as PCB Etching.
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FUTURE SCOPE

According to News Wires, “IndustryARC, in its latest report, predicts that Printed Circuit
Board Market size is forecast to reach $72.3 billion by 2026.”

Their use will increase in wearable electronics, flexible displays, medical

applications and some more like

PCB Board Cameras

Board cameras, alternatively called PCB cameras, are cameras that are mounted directly
onto a circuit board. These PCB cameras consist of a lens, aperture and image sensor and
are designed to take both digital pictures and videos. In all, the cameras are around the
size of a quarter and can be mounted on any size PCB. This means these cameras are
small enough to slip into just about any electronic device.

3D Printed Electronics

3D printing technology is probably one of the most exciting technological innovations

in recent years. From 3D-printed organs to firearms and ammo, 3D printing has
accomplished some incredible things in a variety of industries. The PCB industry is no
different

PCB Autoplacers

Most PCBs today include an autorouter in their design. This PCB component routes
electronic functions throughout a board to model the characteristics of the PCB layout,
therefore making the automation process much easier.
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A Focus on Flexible PCBs

Today's world is incredibly fast-paced, demanding that people and technology move
quickly as well. As the years pass, we expect things to get even faster - that includes
electronics. To allow our devices to keep up with this growing demand for speed, PCB
technology will need to adapt accordingly.

Biodegradable PCBs

Electronic waste, AKA e-waste, is one of the biggest environmental concerns of the
modern era. This type of waste includes electronic items like computers, laptops, TVs,
smartphones and household appliances, many of which contain parts that are neither
biodegradable nor environmentally-friendly. While e-scrapping has become popular in
recent years, e-waste continues to be a problem as people try to find ways to get rid of
old electronics.
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CONCLUSION
Today’s fast-paced and technology-driven world, both people and devices are expected
to operate at unprecedented speeds. As consumer expectations continue to rise and the
demand for smarter, faster, and more efficient technology grows, the printed circuit
board (PCB) industry is being pushed to evolve at a matching pace. In order to keep up
with the accelerating speed of innovation, PCB technology must become more agile,
compact, and adaptive.

Market analysts projected that the flexible PCB market would surge to $15.2 billion by
2020 and reach $27 billion by 2022, a clear indicator of their rising importance. This
explosive growth is not surprising given the versatility, space efficiency, and design
freedom that flexible PCBs offer. Unlike traditional rigid boards, FPCBs can conform to
the dynamic and irregular shapes required by next-gen devices, all while maintaining
electrical performance and durability.

As this trend continues, the industry can anticipate a significant increase in demand for
flexible PCB designs. Engineers, manufacturers, and designers alike will need to innovate
around these flexible platforms, creating more robust manufacturing techniques,
developing new materials, and refining simulation tools to accommodate complex, curved
architectures. In essence, flexible PCBs are not just a product—they're a gateway to
the future of electronics, allowing form and function to merge in unprecedented ways.