Sooner or later, an electronics experimenter will want to make a printed circuit board, or PCB. Many magazines and websites provide PCB creation illustrations for a circuit featured in an article. Historically, do-it-yourselfers only had limited options when making a PCB. Techniques included custom cutting traces on a proto-board or building an ultraviolet light box for photo etching. In 2011, electronics hobbyists can create professional-quality printed circuit boards at home with minimal effort and expense.
Instructions
1 Generate a PCB layout image. Use the image from the magazine article or website if available. Create a custom board layout with a free PCB layout program (See Resources). Ensure a mirror image by using the "flip horizontal" function. Print the layout on a laser printer using the glossy side of photo-quality printer paper.
2 Prepare the copper-clad board for etching. Clean the entire board with fine steel wool. Ensure that the board is dry and free of finger prints.
3 Transfer the layout mask to the copper-clad board. Place the PCB layout image glossy side down on the board. Tape the image in place with masking tape. Turn a clothes iron to the "wool" temperature setting. Place the board on a hard surface. Use firm pressure to iron the paper on the copper-clad board. Toner from the laser printer's image is transferred to the surface of the copper-clad board.
4 Remove the paper from the copper-clad board. Do not simply lift the paper off the board, as this disturbs the toner that will become the etching mask. Instead, place the board into a bowl of warm soapy water. Allow enough time for the paper to become soft and flake off. Gently rub any remaining paper off with your fingers.
5 Inspect the board. All areas not covered with black toner will be removed by the etching solution. The dark lines become the circuit board's traces, and toner masks or protects those areas from etching. Ensure that the traces are continuous without any breaks. Touch up the traces with a permanent marker as needed.
6 Etch the copper-clad board by placing it in a glass pan of ferric chloride etching solution. Remove the board when all the bare copper has been etched away. Rinse the board with cold water. Rub the toner off the traces with fine steel wool.
7 Drill the holes for the component leads. Use a drill press and the properly sized bit for your application. Drilling the holes by hand is difficult but possible.
