1. QRP Page 1 Toner Transfer Method for PCBs One ham’s first attempts to make PCBs at home Jim Larsen, AL7FS 907-345-3190 AL7FS@AL7FS.us Ver 1.0 3/22/06 By Jim Larsen, AL7FS

2. QRP Page 2 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

3. QRP Page 3 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

4. QRP Page 4 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??

5. QRP Page 5 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

6. QRP Page 6 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

7. QRP Page 7 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 friend’s shear

8. QRP Page 8 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

9. QRP Page 9 Dip Trace – Draw the Schematichttp://www.diptrace.com/ Diptrace has a Free Version: Freeware edition does not support export to DXF, Gerber and N/C Drill, max. number of pins — 250.

10. QRP Page 10 Zapper Schematic

11. QRP Page 11 Diptrace Convert to PCB –Step 1 Next Step is to move the components to the layout you would like.

12. QRP Page 12 Run AutoRouter Scale 400%

13. QRP Page 13 Print to Transfer Paper Tried Inkjet Photo Paper with zero success Tried Inkjet Photo Paper with zero success Plain Costco bulk white paper worked Plain Costco bulk white paper worked

14. QRP Page 14 Clean PCB Board Tarn-X First Board was old with fingerprints Dishsoap and hot water Scrub down with rough green scrub pad from Carrs Don’t touch surface from here to the end

15. QRP Page 15 Transfer Toner to Board Or Use a Clothes Iron

16. QRP Page 16 Remove Paper from Toner Soak 20+ Min. Warm, Soapy Water

17. QRP Page 17 Rub off the Paper

18. QRP Page 18 Rub off the paper

19. QRP Page 19 Circuit Ready for Etching

20. QRP Page 20 Choices at This Point Etch all Four circuits Etch all Four circuits Need to touch up traces and Pads Need to touch up traces and Pads Cut the best board free of others Cut the best board free of others Needs No touchup – 3 good 1 bad Needs No touchup – 3 good 1 bad Uses less toner Uses less toner Cut with hack saw, finish w/file Cut with hack saw, finish w/file Find a shear for cleanest cuts Find a shear for cleanest cuts

21. QRP Page 21 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 – That’s too long

22. QRP Page 22 Etching the Board Used a throw-away brush to gently wipe the surface and keep fresh solution on the copper

23. QRP Page 23 Etching the Board Copper slowly is eaten away Only the circuit will remain

24. QRP Page 24 Etching the Board The Etching is complete Some circuits are good, others not good

25. QRP Page 25 Etching the Board This one looks pretty good but with some pitting

26. QRP Page 26 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

27. QRP Page 27 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

28. QRP Page 28 Cleaning up the Traces Solder Paste rubbed on circuit Temp. – 750 F Solder Wick = solder brush Paint the traces with Solder

29. QRP Page 29 Cleaning up the Traces Solder on traces protects the copper from corrosion

30. QRP Page 30 Additional Cleanup Poor traces repaired with small wire and soldered into place

31. QRP Page 31 Additional Cleanup Poor traces repaired with small wire and soldered into place

32. QRP Page 32 Finishing touches Small drill press is a requirement Small diameter drill bits need drill press Drill bits need to be carbide tip drills Don’t breath the dust from drilling

33. QRP Page 33 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 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 Solder in the components Test the circuit Test the circuit Install in a chassis as desired Install in a chassis as desired

34. QRP Page 34 Final Comments This is my first attempt at toner transfer. This is my first attempt at toner transfer. I offer my observations as a learning tool I offer my observations as a learning tool I plan to keep trying new techniques I plan to keep trying new techniques There are Many variations on this technique There are Many variations on this technique Board cleaning methods used by me not best. (e.g., the acetone black smears) Board cleaning methods used by me not best. (e.g., the acetone black smears) My etching technique undercut some traces (Needs major improvement) My etching technique undercut some traces (Needs major improvement) Great potential with this technique Great potential with this technique Give it a try Yourself !!

35. QRP Page 35 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”

36. QRP Page 36 Alaska QRP Club No officers, no directors, no constitution & No dues. Meets the Third Friday of every month - 7:00 PM (Some show for dinner at 6PM) Meet at Dennys (in the back room) on DeBarr near Bragaw. Contact is Jim Larsen, AL7FS, 907-345-3190. AL7FS@AL7FS.us http://www.qsl.net/kl7aqc/

37. QRP Page 37 Questions?