Printed circuit boards (PCBs) provide hobbyists and electronics manufacturers with an affordable and efficient method for laying out and connecting electronic components. Unlike protoboards and perfboards, PCBs are custom designed for each project, and when they are designed properly, you do not need to add any wire between copper tracks to connect components. A single-layer PCB is made of fiberglass with copper foil on one side. You can make a custom PCB at home with a computer, basic tools and etching chemicals.
Instructions
Design the Circuit's Layout
1 Arrange the electronic components on a breadboard or perfboard. Double check the layout against the schematic for errors.
2 Move the components on the board until the layout is the same size or smaller than the PCB.
3 Launch your graphic design or PCB layout software on your computer. Create a document that is the same length and width as your PCB.
4 Draw the circuit's layout in the software. Use black lines that are between 1/100 inch and 5/100 inch wide for the copper tracks. Thicker lines might be easier to work with for beginners. Use circles to represent each drilled hole on the board that will accommodate a component. Each circle consists of an empty space in the middle that is 3/100 inch wide and a stroked line around the circle's perimeter that is 2/100 inch thick. The empty space in the circle represents the size of the drilled hole. If you are using a drill bit that is larger or smaller than 3/100 inches wide, adjust the size of the circle to match the size of the drill bit.
5 Label each circle with the name of the component that is going to be soldered there. Compare the circuit layout to the schematic to check for errors. Flip the image horizontally.
Print the Circuit's Layout
6 Remove a piece of glossy, thin paper from a magazine or catalog -do not use the cover. Choose a page with a white background and a small amount of printed content, such as a text-only page.
7 Cut the piece of magazine paper with your scissors to a size suitable for your printer.
8 Set the laser printer to its best quality setting. Do not use economy mode or any mode that reduces the amount of toner used. Feed the magazine paper to your printer manually as you print the layout to avoid a paper jam. Alternatively, tape the magazine paper to your regular printer paper and feed the paper to the printer. Print on the side with the magazine paper.
9 Cut off the excess paper around one of the printed layout's corners.
Prepare the PCB for Etching
10 Clean the copper side of the blank PCB with a kitchen scrubbing pad and water until shiny. Remove all dirt and oil from the board, and use soap if necessary. Avoid touching the copper with your fingers, and wear clean gloves if necessary.
11 Empty the water out of your iron, and set the iron to the highest heat setting. Turn off the steam, and wait for it to heat up.
12 Tape the PCB to a hard, flat surface with the copper side up. Do not put any tape on the copper side.
13 Place the printed paper on top of the PCB with the printed side down. Align the layout with the board so that it does not go off the board's edges. Tape the paper to the surface you are working on to keep it in place.
14 Press the iron on the magazine paper and PCB firmly for one minute. Use a lot of pressure, and do not move the iron.
15 Iron the paper for four more minutes while applying heavy pressure. Move the iron slowly over the paper and PCB. Do not allow the paper to move. Wait for the board to cool.
16 Trim the excess paper around the PCB, and fill a plastic container with cold water. Place the PCB in the water, and wait for the paper to soften, which might take up to five minutes.
17 Peel or lightly rub off the wet paper with your hands. When you are done, you should see the layout on the copper side of the board clearly.
Etch the PCB
18 Put on safety goggles, rubber gloves and a plastic apron.
19 Put the hydrogen peroxide in a plastic container. Slowly pour in the hydrochloric acid. Do not use a metal container as the mixture corrodes metal. Use a well-ventilated space.
20 Place the PCB in the mixture carefully with the copper side down, and use plastic tongs. Wait three to four minutes, then lift the board with the tongs to check if the copper around the tracks has dissolved. If it has not, place the board back in the mixture and check it every two to three minutes.
21 Remove the PCB from the mixture with your tongs. Rinse it with water.
22 Lightly soak a paper towel with lacquer thinner. Rub the toner off the copper side of the board.
Drill the Holes
23 Install a 3/100-inch high-speed or cobalt steel drill bit in your drill. If your layout uses a different circle size, use a drill bit that is the same size as the empty part of the circle.
24 Drill holes into each of the circles on the board slowly. Do not apply pressure or the board might break.
25 Wipe debris off the board with a scrubbing pad.
