Electronics Production
This week was focused on learning the basics of electronic production, which is the process of designing, fabricating, and assembling a circuit board. Until now, I had mostly worked with breadboards or pre-made boards, so this was my first time making a custom PCB from start to finish.
While working on the electronic production assignment, I realized it's not just about making a board—it's a whole process that involves understanding tools, components, and careful steps from design to testing.
it’s about learning an entire ecosystem that powers almost every modern device around us. Here's how it breaks down technically and why it's such a big deal in the real world:
What Is Electronic Production Technically?
Electronic production is the process of converting a digital circuit design into a working physical board. It involves several stages:
Schematic Design – This is the blueprint. Every component (resistor, microcontroller, etc.) is digitally placed and connected using software like KiCad or EasyEDA.
PCB Layout – This is where traces (copper paths) are routed between components.
DRC (Design Rule Check) – This ensures your design follows rules based on manufacturing limitations.
CAM Processing – Generating Gerber and NC drill files, which are understood by CNC machines or PCB manufacturers.
PCB Fabrication – Milling, etching, or printing the copper board to match the design.
Soldering Components – Carefully placing and attaching components either manually (hand soldering or heat gun)
Testing – Using multimeters, oscilloscopes, or firmware to verify if the board works as intended.
Why Electronic Production Is a Big Deal in Industry?
Backbone of Electronics Manufacturing
Every electronic device—from a simple remote to complex robotics—relies on PCBs. Efficient electronic production allows for mass manufacturing and consistency across products.
Customization & Rapid Prototyping
In industries like IoT, automation, and medical tech, rapid prototyping of PCBs allows engineers to test concepts quickly, saving time and money.
Miniaturization & Precision
Modern products demand smaller and more complex boards. Electronic production helps achieve this with precision design tools and machines.
Automation & Scalability
Techniques like SMT (Surface Mount Technology) and automated soldering lines allow factories to produce thousands of boards with high accuracy.
Sustainability & Optimization Optimized designs reduce material waste, power consumption, and heat generation, which are major industrial priorities today.
Group Assignment
Group Assignment: PCB Design Rules + Production Workflow
Part 1: In-House PCB Production — Design Rule Characterization We used our in-house PCB milling machine (CNC) to characterize the design rules. These settings helped us optimize accuracy, avoid broken traces, and reduce trial-and-error.
Important Checks:
Traces needed to be >0.4 mm apart to avoid merging.
We maintained 0.2 mm clearance between pads and traces.
Bit broke once when plunge was too fast — slowing down helped.
Part 2: Workflow to Send PCB to a Boardhouse
We also documented the process to send PCBs to an external board manufacturer (like PCBWay or JLCPCB):
Design in KiCad: Board layout, footprints, track width & spacing matched fab standards.
DRC Check: Used the boardhouse's specific design rules file (min width, hole size, etc.).
Generate Gerber Files:
Top copper
Drill files
Outline
Soldermask (if needed)
Zip & Upload: Uploaded the zipped Gerber folder to PCBWay.
Review + Payment: Chose color, thickness, finish, and confirmed preview.
Shipping: Estimated delivery time and payment complete.
This helped us understand how tolerance and finish expectations differ between in-house and outsourced PCBs.
What We Learned
The importance of tool diameter and feed rate in determining how cleanly and precisely copper is removed.
Breaking bits is common if plunge is too fast or if depth is overdone in a single pass.
Outsourced boards offer much finer resolution, multilayers, and better finishes — but take longer.
In-house is perfect for prototyping and testing quickly.
We understood the real difference between Gerber export and G-code generation.
Mihir page includes details of test runs on the Roland SRM-20, calibration of depth, and generating test PCBs with different trace widths to finalize reliable values for group use.
My Key Takeaways
1.Learned how to export and read Gerber files.
2.Understood how cutting depth and plunge rate affect trace quality.
3.Found out how Mods workflow converts images to toolpaths.
4.Got a real sense of machine limitations vs. professional boardhouse capabilities.
Individual Assignment
Schematic Circuit Design
Earlier, while designing the schematic, I initially connected each point with wires, but it quickly became cluttered and hard to follow. That’s when I realized that the schematic is meant to be a clear reference for actual implementation, so it should be structured in a way that makes it easy to read and follow. Keeping this in mind, I reorganized the connections to be neater and more structured, ensuring better clarity without unnecessary overlaps. This not only made the schematic look cleaner but also helped in troubleshooting and assembling the circuit more efficiently.
I ensured that all 5V, 3.3V, and GND connections had multiple ports available for easier expansion. Similarly, I made sure to properly allocate SDA, SCL for I2C communication, TX, RX for serial communication, and MISO, MOSI, SCK for SPI connections. This way, the schematic remains organized and scalable, allowing for additional modules or components to be connected without rewiring or running into layout issues.
Run a Design Rule Check (DRC) to identify any errors in the schematic and PCB layout. This helped catch issues like unconnected nets, overlapping traces, and clearance violations. After reviewing the errors, I made the necessary corrections to ensure proper connectivity and a clean design. Running DRC before finalizing the PCB helped prevent potential issues during manufacturing and assembly.
Closed all open points.
Converting to Footprint
This was Fun.
TANK became my inspiration for outlie. Tank is sturdy, balanced, and well-structured The broad base gives more room to place components neatly, so things don’t get too cramped.
It looks like interior of a mini tank...
Mounting holes were incorporated to make installation easier and more secure. This ensures the PCB can be firmly attached to an enclosure or chassis, preventing movement and reducing strain on the components. Plus, it helps with better cable management and keeps everything neat and stable!
Generating PCB Fabrication
Before fabrication, I ensured the design was error-free and optimized. This meant running a Design Rule Check (DRC) to catch potential issues like overlapping traces or incorrect spacing.
I carefully exported the Gerber and NC drill files, making sure all layers (copper, silkscreen, drill holes) were properly aligned.
Any mistake here could mean a faulty PCB, so double-checking everything was a must!
Analysing the Software
Before running the machine, I loaded the design into PCB software (like KiCad or EasyEDA) and carefully checked the layout.
I verified trace widths and clearances to avoid short circuits, ensured proper layer alignment, and, if possible, ran a simulation to check circuit behavior. This step is like debugging code before running it—catching mistakes early saves a lot of time
About the Machine
I carried out the PCB milling using the Roland SRM-20 CNC machine.
Running the Machine
Next, I selected the right cutting bit—a larger bit for rough cuts and a smaller bit for fine traces and drill holes. Changing the bit required loosening the collet, inserting the new bit carefully, and tightening it securely. If not done properly, the bit could slip and ruin the cut.
This is where the actual PCB takes shape! First, I made sure the machine bed was completely clean—even small dust particles can cause misalignment. Using a vacuum cleaner, I removed debris from previous jobs. Then, I carefully set the X, Y, and Z axes, ensuring the machine knows the exact starting point for accurate milling.
Let the machine do its work while keeping a close eye on the process.
Post Milling Process
After the PCB was milled, I cleaned the board thoroughly using a vacuum cleaner to remove any fine copper dust or debris. This was important because even tiny particles can affect the performance of the board during soldering and testing.
ERROR
Allignment Isuues got in my way!
While I was setting up my file in 'CopperCam', the first layer i.e engraving was on different layer setting and another file cutting out border was on different layer. This led to ,misalignment of bed. Due to this, few of inner connections got cut with contour.
Finally Making it Work!
The PCB turned out all safe this time—no errors, finally! After a messy attempt, I made sure to set the axis properly, so there were no weird misalignments. Cleaned the machine bed thoroughly (because a tiny dust particle can ruin everything!) and exported the design carefully in the correct format—no missing traces this time.
Watching the machine do its job smoothly felt like a mini victory. It’s such a satisfying moment when everything goes right, and you get a perfectly milled PCB with crisp traces and no short circuits. Feels like I’ve cracked a secret PCB-making ritual!
Included name as well! this made board more personalised. This was first time.
Soldering Circuit Board
When it came time to inspect, I grabbed a microscope to get a close look at the LEDs and all the solder joints. It was wild seeing how tiny everything was under the scope!
I started by getting everything together—PCB, components like LEDs, resistors, and of course, the Yihua 853D heat machine and a regular soldering iron. Made sure everything was ready before diving in.
The first thing I tried was using wax and a heat gun for the SMD components (like the tiny LEDs and resistors). I carefully applied a bit of wax on the pads where the components would sit. The wax helped keep everything in place while I heated it up with the heat gun. Watching the wax melt and the components settle into place was surprisingly satisfying!
Next, I got to work with the regular soldering iron for the rest of the components. I made sure the solder went neatly around the pads, and I had to be extra careful with the tiny SMD components. I didn’t want any bridges, so I had to be super precise.
Finally, I powered the board on to check if everything was working. I ran a quick test to make sure all the connections were solid and the components were behaving how they should.
After all the testing, I cleaned the board with a brush to get rid of any flux and gave it a final once-over.
The LED Blinked
The PCB board actually worked! After a few bumps along the way (and let’s be honest, plenty of moments when I thought I might’ve totally ruined it), everything finally came together.
Using wax and a heat gun for the SMD components? was very convinient and something new to learn. And even though the soldering iron and microscope made me second-guess every tiny detail, once I got the board tested and everything lit up as it should, I couldn’t believe it.
I honestly felt like I’d just completed an epic challenge. This assignment taught me not only the technical side of soldering but also the patience, precision, and sheer persistence needed to get things right. I’m way more confident now and honestly proud of how everything turned out. Can’t wait to tackle the next project and hopefully level up even more!