The PCB manufacturing process is a journey to turn the design into real PCB. During this process, engineers use specialized software to create the circuit layout and generate it as a set of Gerber files, the industry-standard blueprint for fabrication.
The core manufacturing process starts with a laminate panel coated with copper. We use a light-sensitive film called photoresist. And the Gerber data is used to expose UV light through a photomask, transferring the circuit pattern onto the panel. We then wash away the unexposed areas, leaving a protective layer on the copper.
Next, the panel undergoes etching, where a chemical solution removes the unwanted, unprotected copper, leaving behind the precise copper traces and pathways. Drilling follows, where computer-controlled drill bits create microscopic holes for vias (which connect layers) and component leads.
These holes are then made conductive through a complex electroless copper deposition process, plating a thin layer of copper onto the walls. Electroplating further strengthens this copper layer. We then use solder mask over the entire board, typically green, insulating the copper and preventing solder bridges. We coat the exposed pads are with a surface finish, like HASL or ENIG, to protect them from oxidation and ensure solderability.
Finally, silkscreen printing adds labels and identifiers for components. Each board undergoes rigorous Electrical Testing to verify connectivity and isolate any shorts or opens. After a final quality check, we use machine to route the panels into individual PCBs, ready for component assembly. This intricate, multi-step process transforms a design into the essential backbone of all modern electronics.
During the production, there are many critical issues that the manufacturers need to pay more attention to. Such as the Gerber File Format, Material Selection, Process Control, Quality Control & Testing, Environment & Management and so on. Many manufacturers in China, like Sayfu, Sugar and Kinwong, etc. They usually set intermediate inspection process to guarantee the qulity and lower down the unnecessary cost.
To sum up, PCB manufacturing is a precise and interlinked process where negligence in any single step can lead to mass issues. Therefore, partnering with an experienced PCB supplier that maintains strict process controls and engaging in thorough communication. During the design phase are the most critical prerequisites for ensuring PCB quality and reliability.
