Electronics production

In our FabLab, we have the LPKF ProtoMat S63, a high-precision PCB milling machine designed for rapid prototyping. It allows for milling, drilling, and structuring of printed circuit boards with exceptional accuracy.

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In-house PCB production process

Technical Specifications

Feature	Specification
Workspace	229 mm × 305 mm × 35 mm (Z-axis: 22 mm)
Automated Tools	15 positions
Milling & Drilling Spindle	60,000 RPM
Precision	100 µm
Special Functions	Automatic tool change, double-sided milling with fiducial alignment

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Key Features

• Automatic Tool Change
  The ProtoMat S63 features an automatic tool changer with 15 positions, allowing seamless switching between different milling and drilling tools during operation, increasing efficiency.

• High-Speed Milling & Drilling Spindle
  With a 60,000 RPM spindle, the machine ensures precise PCB processing. It supports a minimum structure size of 100 µm, making it suitable for fine-detail work.

• Double-Sided PCB Milling
  The machine supports double-sided PCB milling by using fiducial markers for precise alignment. This ensures accurate layer registration when processing both sides of a board.

• Large Workspace
  The 229 mm × 305 mm workspace allows for the processing of medium-sized PCBs, making it ideal for prototyping and small-batch production.

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Applications

• PCB prototyping for research & development
• Microstructuring of materials for sensors and electronics
• RF and high-frequency PCBs requiring precision milling
• Double-sided PCB fabrication using fiducial alignment
• Small-scale production for electronics projects

The LPKF ProtoMat S63 is a powerful solution for rapid and precise PCB prototyping, eliminating the need for complex chemical processes.

Testing the trace width

To test the smallest achievable trace width we first converted this image to a footprint with KiCAD’s image converter.

In there we opened the file, changed the output format to generate a footprint for the front copper layer and exported it to the clipboard.

After closing the image converter we headed over to the PCB editor and simply pasted in the footprint, followed by giving it an outline on the Edge.Cuts layer.

We then clicked on File -> Fabrication Outputs -> Gerbers (.gbr) and only selected F.Cu and Edge.Cuts before clicking on Plot to generate the files needed for production.

With that done, we started up the machine and software that guided us through the process of milling our board.

In the software we used the SingleSided_Top template and imported our files.

Something must have gone wrong.

We redid the image conversion with a Black / White threshold of 100 and tried again.

Much better…

Next we opened the Technology Dialog where we set the isolation method to Complete Rubout and contour routing to Horizontal Gaps while disabling processing for the Drills, Fiducials, Pockets and Blind Vias tabs.

Computation showed no errors and left us with the following toolpath.

We then checked the tool magazine to see if all the tools we needed for the job were loaded and in good shape.

The board production wizard guided us through loading up and securing the material, as well as finding the right place for our board.

After that it automatically started warming up the spindle motor and began milling the top layer.

When the job was done, we cleaned the machine and seperated our board from the sheet.

Our machine passed the test with flying colors, here is a quick look under the microscope:

Workflow for sending a PCB to a boardhouse

1. Preparing the Gerber Files

Before we can order our PCB from JLCPCB, we need to export the Gerber files from our design. Since we are manufacturing a single-sided PCB, we only need the relevant layers.

Steps in KiCad:

1. We open our PCB design in KiCad.
2. Under “File” → “Plot”, we select the Gerber format.
3. We enable the following layers:
4. F.Cu (Top Copper – traces and pads)

5. Edge.Cuts (Board Outline – defines the PCB shape)
   (In our case we wanted only the PCB board without electronic components. This is why we only used the two layers.)

6. We click “Plot” to generate the Gerber files.

7. Then, we go back and select “Generate Drill Files” to create the Excellon drill files.
8. Finally, we compress all the generated files into a ZIP file, which we will upload to JLCPCB later. Only ZIP files works with this website.

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2. Uploading the Gerber Files to JLCPCB

1. We visit the JLCPCB website.
2. We click on “Order Now” or “Quote Now” to proceed to the upload page. (There is also a fast window to order it on the home site)
3. We drag and drop our ZIP file into the upload area or click “Add Gerber File” to select it manually.
4. After uploading, JLCPCB processes the file and displays a preview of our PCB. Here, we verify that all layers are correctly displayed.

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3. Configuring PCB Specifications

Since we are ordering a single-sided PCB, we select the following settings:

• PCB Layers: 1-layer (1 Layer PCB)
• Material: FR4 (standard)
• Thickness: 1.6 mm
• Copper Thickness: 1 oz (35 µm)
• Color: Green (default) or another available color
• Surface Finish: HASL (cost-effective)
• Minimum Drill Size: 0.3 mm
• Quantity: Default is 5 pieces, but we can order more

Once we have configured everything, we click “Save to Cart” to proceed.

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4. Completing the Order

1. In the cart, we review the PCB specifications one last time.
2. We select a shipping method (e.g., DHL, FedEx, or other options).
3. We enter our shipping address.
4. We choose a payment method (PayPal, credit card, etc.).
5. We finalize the order by clicking “Place Order”.

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5. Shipping and Tracking

• After placing the order, we can track the status under “My Orders”.
• Once the PCBs are manufactured and shipped, we receive a tracking number.
• Delivery time depends on the shipping option chosen (express takes around 2-4 business days, while standard shipping takes longer).

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With this guide, we can successfully order our custom PCB from JLCPCB. 🚀