Home Prototyping
     Welcome to Easyamp, here you will find information about do it yourself audio electronics
and related audio.
Amplifiers PrototypingEducation
   
    Be sure and wash your hands before handling the copper stock. In about a week the unused copper will be tarnished and in need of some serious scrubbing from the oils and other stuff on your hands.



I use dry etch transfers to make my boards but there are other methods I believe require less time like, presensitized copper stock but I'll go into more detail on presensitized boards as soon as I do it myself. Keep in mind if you are using a schematic editor such as Eagle to create your boards the bottom traces of your boards need to be mirrored when printed and the top layer does not. All posted schematics should be in 1:1 scale so you do not need to adjust the images for them to be the correct size for your PCB components after printing, but check this before you create your traces by taking a PCB component with fixed leads like an output transistor and lay it over it's position on your printed schematic. If everything checks out ok cut your printed schematic out of the paper and lay it over the copper and trace around the edges of the schematic onto the copper so you can cut out a piece of copper the same size as your schematic. Tape the schematic to the copper, get an all, or something with a point, but not to sharp and tap indentations into the copper where you will need to place the components and any via's (through holes) your project calls for, this will ease the drilling later on.You will only need to do one side and once your done double check your hole punche's before you drill.

Drilling

Drilling without a drill-press can be tricky to do correctly, you need to be careful because the bit size you need is only 3/64 and can snap with a shaky hand. It helps to put the bit in the chuck as far as it will go or out as far as you can get it when not using a press. As far out will let the bit have some flex before it snaps and as far in will make it more likely to snap from bending (not as much room for flex) but if you can get it all the way in so that just a little bit sticks out it will be much harder to break. These bits are sometimes tough to find and if have trouble finding one you can buy the 7 piece drill bit set from Dremel (Model#628D) this set even includes a 1/32 drill bit. Now if you have a drill-press then remember not to push to hard or the copper on the opposite side will push through and not get cut by the bit but just get all screwed up and look messy. Be sure and double check that you got all the holes.

drill press

Transfers

I use dry etch transfers most of the time to transfer the schematic to the the copper. The use of dry etch transfers is pretty straight forward, you place the transfer over the copper where you need a trace, referring to you schematic, and rub it on. Wash the copper before you start placing the transfer to assure uniform contact between the copper and transfers. I Usually start by placing a circular transfers over all the holes top and bottom before (if double sided) I start with the traces. Now mimic your paper schematic top and bottom if applicable, on the copper and when you have all the traces down lay the board in between to sheets of paper or whatever and press all over the board to make sure all your traces are down tight. And as always double check your work, if you mess this stage up, and etch it, you'll have to start all over . You usually don't find out until you go to place your components and as I'm sure you can imagine it's not a happy moment.

 

Etching

When you are ready to etch the copper you should be in a well ventilated area and lay down something water proof like Handiwrap or wax paper in case you spill any of the Ferric chloride. Ferric chloride will stain anything it touches except most plastics and glass. If you warm the ferric chloride first it will etch the copper faster but be sure not to heat it up to much or the dry etch transfers will bubble and ruin your board. I use those cheap glad tupper wear like dishes to etch in and they seem to hold pretty well. Pour enough ferric chloride into the etch tub so your board is completely submerged and stick it in the micro wave for about 5~10 seconds or until warm but not hot, if it gets hot wait until it cools before you put the copper in or you may have to start over. Slowly agitate the copper by moving the etch tub and in about 5~7 minutes you should see the copper washing away. After about 12 minutes or so you should almost be done and when all of the exposed copper is removed remove the finished PCB and dispose of the etchant. I read the MSDS on Ferric chloride after hearing I could pour it down the toilet and didn't see any reason why not. If you have any pets that like to drink out of toilet be sure and flush a couple times just in case. Now using the edge of credit card or plastic something or other scrape off the the dry etch transfer's left on the board. Give the board another quick bath and light scrub with some fine steel wool to clean the copper for soldering.

 

drilled, ecthed, and tinned

Tinning

Ok now you should have a nice PCB in your hands if you like you can use tinning solution or Fluoboric Acid to tin the copper and give it a nice professional look as well as protect the copper from tarnish. I usually just cover the exposed copper with solder while soldering but if you have a large project this could get very time consuming. When you place your components work from shortest to tallest for obvious reasons, and pre-place your components if possible to make sure everything fits. Check that you're putting things on the top side of the board and solder away. Also bending the leads of components helps when soldering to hold the components in place but keep in mind if something goes wrong you may need take out a component or two and it's pretty tough if the leads are bent over.

Soldering is something you get a feel for, it can be shown and there are guidelines and information for soldering but I learned to solder by soldering. Here are few things I've learned along the way: keep a small tub with a sponge submerged in water to clean the iron tip repeadly this is important with hot irons. Try and make contact with the board first and push solder to the device lead to keep from heating the device to much. If the joint is solid the solder will be cone shaped. Keep your tip to a point by grinding, cuttin or whatever so you can get it into tight places. Keep a little bit of solder on your tip for a more even and faster heat transfer. Electronic componets due have a maximum heat and heat-time that can be applied while soldering, refer to the data sheet.

after componet soldering

 

And the finished board. This is an output driver board used to sink and source current to drive a set of output transistors, or it could be a high voltage opamp. If you replace the 50v bypass cap's with higher voltage devices then this baord can be used all the way up to 100v's+ per rail or 200v's+ total, not that you'd ever need it but just in case. I have used mpsa42~92 combo for small signal and mje340~350 combo transistors for drivers.

Finnished project