Printed circuit board (PCB) prototypes can be extremely helpful during the PCB manufacturing process because they provide a means of testing multiple aspects of the designed component before it is mass produced. Fabrication and assembly of PCBs and PCB prototypes varies significantly, although the two components share many similarities as well.
Prototype Fabrication
When ordering a PCB prototype, be sure that the prototype fabrication shop can meet certain expectations. If time is of the essence, a shop needs to be able create a prototype in 24 to 48 hours. Up–to-date technology is equally important, especially when it comes to handling difficult specifications, such as PCBs with minimal trace spacing.
When it comes to fabricating PCBs with small dimensions, smaller drills and laser technology are viable options. A fabrication shop should be well equipped to handle even the most complicated PCBs by maintaining a supply of specialty tools and drill sizes. Surface finish options should be available as well, including gold and silver immersion. Additionally, a shop should be able to create a board with a multitude of different layered materials, including mixed layers, from materials like PTFE and polyimide.
Other PCB specialty procedures, such as depth drilling and sequential lamination, may be offered by a fabrication shop, but if these processes are needed be sure to check in advance. Sequential lamination requires that boards be laminated two at a time instead of as one large batch. Depth drilling is used when holes need to be drilled to a specific depth without breaking through the other side of the circuit board.
Running a Successful Prototyping Line
There are many considerations involved in running an in-house prototyping line. Prototyping is a process that entails constant change, re-design, and regeneration. In order to accommodate the process, the line should be as flexible as possible to enable quick incorporation of new parts and designs, or, if necessary, restarting the prototype run.
Because a prototype may change substantially throughout the testing process, it’s important that a prototyping line can incorporate PCB prototypes of different sizes and that the prototyping machines can be reconfigured to account for these changes. A machine that cannot be easily adapted to meet changing specifications is not well-suited to creating a smooth prototyping line.
Part inspection, specifically automatic optical inspection, should be included in the line to check all final components for flaws. If a shop is used, check to ensure that layer inspection is available and verify how many layers will be built into the prototype.
A final consideration concerns the technicians operating the line. If a technician is comfortable operating multiple kinds of devices and programs, this may expedite the process by making ample use of his or her expertise to handle changes in production as they arise.
