PCB Making

The Toner Transfer Method

The toner transfer method is actually based on the same principal as the professional PCB making process, but instead of using the expensive photo film and photosensitive material to transfer the PCB drawing layout to PCB copper; we use the laser jet printer toner to do the job.

The laser jet printer toner actually contain a plastic material and not an ink as the deskjet printer does; therefore when we print this PCB drawing layout on a glossy paper, the black toner plastic material will be attached only on the surface of this glossy paper; by using enough hot from the house hold iron we could make this black toner plastic material melt and reattached to the PCB copper surface.

Now as the magazine glossy paper and the black toner plastic material attached to the PCB copper surface, we could easily remove the paper part by submerging it in the water; once the paper dissolve and become pulp what is left is the black toner plastic material on the PCB copper surface.

Using the etching process the uncovered area on the PCB copper surface will chemically react with the Ferry Chloride (FeCl3) solution and become dissolved but the covered area will not be dissolved as it being protected by the black toner plastic material. The last step is to remove this black toner plastic material using the nail polish remover and drill the board.

The Making of BRAM-AXE Board PCB

Now as you understand how this toner transfers method work; let’s make the BRAM-AXE board PCB.

The Preperation

• Cut the copper clad laminated PCB to 60×45mm size and smooth it’s surrounding with the sandpaper.

• Wash and scrub the PCB using the kitchen scrub and soap to remove any dirt and grease on the PCB copper surface

• Cut the glossy magazine paper to about half of A4 paper length size and full width of A4 paper size; try to use the paper with less printed image or letter on it, so you could easily examine the printed PCB layout. In fact you could use any glossy paper; but do not use the glossy photo paper as it hard to remove the glossy coating material on the PCB copper surface when the toner has been transferred; just safe it for printing your photo.

• Print it with the laser jet printer on the glossy magazine paper. The other alternative is to print it with other type of printer (e.g. deskjet printer) and use the real copier machine to copy the PCB layout to the glossy magazine paper because the copier machine use the same toner material as the laser jet printer. On this tutorial I used the HP LaserJet P1006 to print this PCB layout.

• When printing the PCB layout you could use the EAGLE software directly or you could use the PDF version of the PCB layout provided here.

The Toner Transfer Process

• Next aligned the glossy magazine paper so the printed PCB layout is facing toward the PCB copper surface and you could lock this paper corner with the tape so it won’t move. Cover the glossy magazine paper with another paper to protect it again the over heating (usually this glossy magazine paper is quite thin).

• Power on the house hold iron and set it to its maximum heat, let it become hot for a while.

• Pre-head the PCB copper surface for about 15 seconds, this will ensure the toner from the glossy magazine paper will transfer perfectly.

• Flip the glossy paper magazine toward the PCB precisely; apply pressure and move gently the iron on the top of the paper for about 45 second, make sure you cover the whole PCB layout. Wait until it become cold, do not remove it while it is hot as it could harm your hand and the black toner plastic material will not transfer perfectly to the PCB copper surface.

• Trim the glossy magazine paper so it has the same size as the PCB. Next immerse the PCB in the water and wait for a couple of minutes than gently pealing all the paper until it all being removed.

• Examine the PCB layout, and make sure all the connection is perfectly covered by the black toner. You could use the marker to repair the tiny un-perfectly covered area or you could repeat the whole process again by first removing all the black toner using the nail polish remover.

The Etching Process

• Prepare the etching solution in the plastic container by mixing four part of water with one part of Ferry Chloride (FeCl3) and it would be better to use the hot water about 40 to 50 centigrade degree because the chemical reaction will be faster at higher temperature.

• Make sure you are wearing the disposal rubber hand glove and the eye protection goggle when working with this Ferry Chloride solution because this chemical acid solution is very corrosive and poison; you should always take extra precaution when working with this Ferry Chloride solution. If you accidentally exposed with this acid solution, make sure you wash it with plenty of water and soap.

• Next immerse the PCB in the Ferry Chloride solution and gently move backward and forward the plastic container so the chemical solution could react with the PCB uncovered copper effectively. Keep watching until all the uncovered copper area becomes dissolved.

• Wash the PCB with plenty of water and soap; make sure you mix the Ferry Chloride solution with the water and soap solution to neutralize this remaining acid solution before you discard it. Usually the Ferry Chloride solution could only be used once, therefore use just enough amount as needed to etch your PCB. As a rule of thumb the acid solution area size should be a least twice as your PCB copper surface area size and the acid solution deep is about 10 mm to 20 mm.

• The last process is to remove the black toner on the PCB copper surface with the nail polish remover (acetone); you could examine the black toner material while you are removing it and you will find out that it’s made from a plastic material.

The Finishing

• Drill the PCB components hole with the 1mm drill bit size and the PCB stand off with the 3mm drill bit size. On this tutorial I’m using the general purpose hand drill to drill this PCB board.

• Again wash and scrub the PCB with water and soap to remove any dirt and grease before you start to solder the electronic components on it.

Component Cost:

Plain copper Board = 20,35 Rs

Ferric chloride = 30Rs 50 grams

 Ink remover can be used as alternative for Acetone