Toner Transfer Method for PCBs

first attempt to make PCBs at home

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Overview of Toner Transfer PCBs

First attempts at Printed Circuit Boards What is toner transfer method? My approach to toner transfer Drawing the Schematic Converting to a PCB layout Preparing the Board, Laying down the Toner Removing the Paper; Leaving the Toner Etching the Board, cleanup and solder coat Drilling, shearing and building Comments and Suggestions
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First Attempts at PCBs

Early years sticky labels cut with a sharp blade Sharpie permanent ink pens for resist Results worked but were pretty simple and crude

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PCBs via Toner Transfer (TT)

Why even build my own boards?

Seemed like fun. Cost can be low. For over 40 years complex Boards stopped me. Manhattan Style building is good but I never seem to get started. Front-end load the hard work; finish with fun.

So What is Toner Transfer Method??

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Toner Transfer Method

A method of creating a printed circuit board (PCB) using a copy machine or a laser printer to make apply the etchant resist pattern Software now available to create schematic and PCB layout No expensive equipment is required but can be helpful in the home A simple process once the basics are mastered

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AL7FS Approach
Equipment in the Toner Transfer Process A computer Free Demo Software Up to 250 pins Laser Printer or Copier Various dishes for soaking or etching A household iron or a laminator Tarn-X, soap, scrubber, Acetone cleaner, surgical gloves, Drill Press Carbide drill bits Shear or other method for cutting PCB

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AL7FS Approach
Equipment in the Toner Transfer Process A computer Already had a computer Free Demo Software DipTrace demo version Laser Printer or Copier Decided to Buy Printer Various dishes - Already had on hand A household iron or a laminator Laminator-eBay Tarn-X, soap, scrubber, Acetone cleaner, surgical gloves Had all but the scrubber Drill Press Decided to buy a small one Carbide drill bits Bought via eBay Shear or other method for cutting PCB Will use a Page 7 friends shear

Lets build a simple circuit:

Zapper circuit schematic. From Dr. Clark's book "The Cure For All Diseases Only the schematic is provided from web source
What to do??

http://www.members.aol.com/mas1911/index.html 8 Page

Dip Tracehttp://www.diptrace.com/ Draw the Schematic

Diptrace has a Free Version: Freeware edition does not support export to DXF, Gerber and N/C Drill, max. number of pins 250.

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Zapper Schematic

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Diptrace Convert to PCB Step 1

Next Step is to move the components to the layout you would like.

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Run AutoRouter

Scale 400%

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Print to Transfer Paper

Tried Inkjet Photo Paper with zero success Plain Costco bulk white paper worked

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Clean PCB Board

Tarn-X First Board was old with fingerprints Dishsoap and hot water Scrub down with rough green scrub pad from Carrs Dont touch surface from here to the end Page
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Transfer Toner to Board

Or Use a Clothes Iron

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Remove Paper from Toner

Soak 20+ Min. Warm, Soapy Water

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Rub off the Paper

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Rub off the paper

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Circuit Ready for Etching

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Choices at This Point

Etch all Four circuits Need to touch up traces and Pads

Cut the best board free of others Needs No touchup 3 good 1 bad Uses less toner Cut with hack saw, finish w/file Find a shear for cleanest cuts

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Etching the Board

I used old Etching Solution 15 years old (Not a good idea) Temperature of solution was only about 68 degrees (Not warm enough) Bottle says up to two hours I took 65 minutes Thats too long
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Etching the Board

Used a throw-away brush to gently wipe the surface and keep fresh solution on the copper
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Etching the Board

Copper slowly is eaten away

Only the circuit will remain
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Etching the Board

The Etching is complete

Some circuits are good, others not good
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Etching the Board

This one looks pretty good but with some pitting

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Cleaning off the Toner

Acetone was used to clean
off the Toner from the circuit pattern Left black smudges on the board No answer for this yet

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Cleaning up the Traces

My etch process undercut
the toner in places I inspected each circuit with a magnifying glass In places I added a jumper to assure continuity

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Cleaning up the Traces

Solder Paste rubbed on circuit Solder Wick = solder brush

Temp. 750 F

Paint the traces with Solder

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Cleaning up the Traces

Solder on traces protects the copper from corrosion

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Additional Cleanup

Poor traces repaired with small wire and soldered into

place
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Additional Cleanup

Poor traces repaired with small wire and soldered into

place
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Finishing touches
Small drill press is a
requirement Small diameter drill bits need drill press Drill bits need to be carbide tip drills Dont breath the dust from drilling

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Final Touches
May Use toner transfer method again to

add component outlines on the top of the board. Can use household iron or laminator to fix the toner Solder in the components Test the circuit Install in a chassis as desired
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Final Comments
This is my first attempt at toner transfer. I offer my observations as a learning tool I plan to keep trying new techniques There are Many variations on this technique Board cleaning methods used by me not best. (e.g., the acetone black smears) My etching technique undercut some traces (Needs major improvement) Great potential with this technique

Give it a try Yourself !!

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Links for Toner Transfer

http://www.diptrace.com/ HomePage for DipTrace software http://groups.yahoo.com/group/diptr/ Mail List for DipTrace
http://groups.yahoo.com/group/Homebrew_PCBs Mail List for homebrew PCBs

http://max8888.orcon.net.nz/pcbs.htm another step by step example http://www.Google.com/ search on toner transfer method Page
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Questions?
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