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Easy PCB (Printed Circuit Board) Fabrication, Using Laser Printer Toner Tran.pdf 137KB

Easy PCB (Printed Circuit Board) Fabrication, Using Laser Printer Toner ...IY at Home; Making, Homemade, Copper, Etch, Etching, Pattern, Electronic

Look at my Used Test Equipment and New Electronic Components!

Gootee Curve Tracer Kit Homepage

Gootee Homepages Index

Easy Printed Circuit Board Fabrication

Using Laser Printer Toner Transfer

This page is going to be mentioned on a TV show!

My printed circuit board webpage (this page) is going to be mentioned on a TV show! I got a call, a few months ago, from a

writer for the Saturday morning television program called "Strange Days at Blake Holsey High".

The episode that he was writing would require the characters to be able to fabricate a printed circuit board (PCB), using a

more-or-less believable method. He found this page with an internet search and then telephoned me. We had a very nice long

chat. (Interesting guy!) And I gave him a procedure that the characters might use to make a PCB, with only what they had on

hand, i.e. no blank PCBs. [It involved using a plastic notbook cover with a piece of metal foil spray-glued onto it, which they

then ironed a photocopied pcb pattern onto, after which they dropped it into some kind of acid. But hey: He said it only had

to be "somewhat plausible".]

The episode, entitled "Brainwaves", should air sometime in October, 2003. According to the script page that was sent to me,

a character will say that they need to make a "Gootee Board", and will mention that it is "named after Tom Gootee, who

posted the instructions on the internet"! Finally!! My fifteen seconds of fame!! Cool, huh?! Maybe I should install a hit-

counter on this page, again, just to see what happens, after that. (Ok. They don't actually mention this page's URL. But it

should be enough that a web search will very-easily find it.)

So check your local TV listings! "Strange Days at Blake Holsey High" is a non-animated Saturday morning show about a

science class at a high school, which airs on NBC (at 11 AM CST, here). It is a half-hour drama/comedy series "where

science fiction meets science fact". The sharp-witted teen characters are "complex, yet believable", and are challenged with

"high stakes, mystery-laden adventures". Besides entertaining, and resonating with, the target audience, the show also

educates, "by encouraging kids to look at their world and ask the questions... "Why?" and "How?"". So check it out!

UPDATE:

It was on! I AM NOW IMMORTAL!!! (Hehe.) Here's what happened, on the show: The science class was trying out a

brainwave analyzer, of some sort, when two of them somehow switched bodies (a nerd and a football jock, no less, hehe).

But before they could attempt to switch back, the machine malfunctioned. They later determined that the circuit board was

fried and that a replacement board from the manufacturer would take several MONTHS to arrive. Then one of the really-

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Easy PCB (Printed Circuit Board) Fabrication, Using Laser Printer Toner ...IY at Home; Making, Homemade, Copper, Etch, Etching, Pattern, Electronic

smart students said, "We'll have to make a Gootee Board.". The teacher said, "A WHO-tee board?". And the student said, "...

It was named after TOM GOOTEE, who posted the instructions on the internet.". It was as plain as day. It seemed like they

actually *emphasized* my name. It still startles me, when I watch the videotape of it. I have since heard from several people,

via email, who have seen the show, too, but, interestingly, on different days than when my videotape copy of it was made.

One was a month or more after the original airing, which was, IIRC (i.e. if I recall correctly), the second weekend in

October, 2003. The other person, my friend Ben Verkamp, saw it just a week or so ago, around the second weekend in

February, 2004. HOWEVER: *HE* SAID that it was mentioned on the "Discovery Kids" show, and that they said

something about making "a Gootee Board" (which woke him up), and that it was "discovered" (Geez! Not "discovered"; just

perfected and written down in detail, so others wouldn't have to "re-invent the wheel".) by Tom Gootee, and that they'd

gotten it off the internet. So I don't know if Ben saw the actual "...Blake Holsey High" episode or some OTHER show called

"Discovery Kids". Or maybe that was the name of the network, or something like that, and he just CALLED it the Discovery

Kids show in his email. If anyone knows, please drop me a line.

I can almost SEE it now: I'm 75 years old and the "...Blake Holsey High" series has become a cult classic among the slightly-

twisted 10-to-12-year-olds of the day. And one of my grandchildren, who previously respected me about as much as he

would Rodney Dangerfield, is ONE of those kids. He comes in, wide-eyed, from the TV room, to where I'm dusting off a

glass display case that holds an antique Gootee Curve Tracer with serial number 0000001, and starts stuttering about hearing

"Tom Gootee" on the TV show that's THE MAIN FOCUS OF LIFE for him and all of his closest friends. ("As plain as

day!", he says. Hehe.) Even better, HIS name ALSO happens to be... Tom Gootee. And life is suddenly good again, for a

while.

UPDATE #2 (It's gone international...):

07/19/04

Everyone,

See the email, below! The TV show that mentioned my name is now being subtitled in Hebrew, for distribution in Israel!

That is the only other country I've heard from about it, so far. But it makes me wonder how many OTHER countries there

are, where that series will be distributed.

My son just saw another re-run of "my" episode, this past Saturday, locally, too.

To refresh your memory, or to see details of that particular episode's dialog and of the series (and some other interesting

stuff), check my website's page about it, at:

http://www.fullnet.com/u/tomg/gooteepc.htm

Regards,

- Tom

----------

From: Alper[SMTP:[email protected]]

Sent: Monday, July 19, 2004 2:50 PM

To: [email protected]

Subject: blake holsey high

hello,

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Easy PCB (Printed Circuit Board) Fabrication, Using Laser Printer Toner ...IY at Home; Making, Homemade, Copper, Etch, Etching, Pattern, Electronic

I just visited your webpage because i was subtitling (hebrew) the episode where you

are mentioned,

and the dialog i was using was wrong. I just thought you will be glad to hear

that you will also have "your moment of fame" here in, Israel (it's a daily show

here, although couple of

years late..). I Enjoyed reading your webpage,best of luck,

Hadar Alper:-)

Making PCBs:

Introduction:

You can easily make your own high-quality PCBs (printed circuit boards), from a laser-printer or copier (but not inkjet)

printout of the desired copper pattern, using an ordinary clothes iron, and, most-importantly, the correct paper type. You can

have finished boards in less than an hour, including printing, preparing the copper board, transferring the pattern, removing

the paper, etching, and drilling. You can also use this method to print the component markings onto the non-copper side of a

single-sided PCB. AND the COST is VERY LOW.

[FAQ about using INKJET printers: I've been getting a lot of email, asking me if an INKJET printer can be used to print the

patterns, for this PCB-making process. The answer is: NO! The toner in laser printers and most copiers is made mostly of

PLASTIC, which resists the acid that eats away the copper that doesn't have any toner on it. Inkjet printers use INK, not

toner. And their ink is typically NOT a good etch-resistor, at all.]

There are many methods that can be used to make a PCB. Most of the traditional methods involve applying a "mask" over

the desired portions of the copper, and using an acid or etchant that can't easily penetrate the mask material to remove the

unwanted copper from the remainder of the surface, although direct mechanical milling-away of the unwanted copper is also

sometimes used.

Most commercial printed circuit boards seem to be made with a screen-printing process, for the mask. There are now

available screen-printing materials that use a laser printout (or any black and white art), and a photo-sensitive screen

material, that allow anyone to make a screen-printing screen, at home, with NO special chemicals and NO special lights (See

http://www.cbridge.com, Circuit Bridge, San Jose, CA. Their "HiRes" product supposedly can clearly reproduce 4-point

type.).

Another popular method, which also works with laser printouts, is photographic in nature: A transparent positive or negative

image of the mask is created, usually photographically, and is used to expose, with a special light, a PCB coated with a

photo-sensitive etchant-resistant material. That seems to be the preferred method, for getting the best quality, finest traces,

most repeatability, etc, at home, or in a low-volume, prototype-oriented situation. However, for many applications, and for

the lowest budgets, the method described below can give results that are at least ALMOST as good, for many applications,

for less money and maybe more quickly.

The reason that this toner transfer method works is that the toner in most laser printers and copiers is composed mainly of

PLASTIC. And the etching chemicals (acids) that are used will eat copper but will not eat plastic.

Very small trace-widths are said to be achievable with the photographic method mentioned above. I have not tried any traces

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Easy PCB (Printed Circuit Board) Fabrication, Using Laser Printer Toner ...IY at Home; Making, Homemade, Copper, Etch, Etching, Pattern, Electronic

that were less than 0.01-inches wide, with the toner-transfer method, described below. However, I have had absolutely NO

problems, at all, with the 0.01-inch (10 mil) traces. So, I assume that the achievable lower-limit is MUCH less than 0.01-

inches.

The Toner-Transfer Method:

The type of paper used is the KEY. Almost all types of paper will work, to some degree. But there are usually two problems:

1) Print quality: Some papers print with tiny (or large!) pinholes in the toner, which greatly degrades the quality of the

finished copper traces. 2) Removability: The paper has to be able to be removed, relatively easily, without causing any

damage to the pattern on the copper. Glossy, coated inkjet-printer-type paper has been found to work very well, since the

coating on the paper will usually separate from the paper, especially when soaked in water.

I've recently tried MANY different paper types, and have finally found one or two that give excellent results for making

PCBs (printed circuit boards) via a laser printer or copier printout and the household-clothes-iron toner-transfer method.

I tried almost every glossy paper type that our local Staples office-supply store carries, plus the "house glossy" from our

local printer. Most either had "pinholes" in the large black areas, or in the vertical (parallel to the print path) areas, or had

removal problems after ironing. For example, the HP Premium Photo Paper had perfect printing, with no pinholes at ALL,

ever. But, it was almost impossible to remove, even with long soaks in soapy hot water, or in alcohol, and often pulled the

traces off with it. Anyway, I finally found a good paper that's always free of pinholes and still removes fairly easily. It also

leaves extremely strong toner/traces on the copper, which can be scrubbed fairly hard with a toothbrush, or rubbed very hard

by fingers, without being damaged.

(UPDATE: See farther below, for the correct paper type that is currently available.) I had originally found that this paper

worked well: the JetPrint "Graphic Image Paper, Gloss Finish", Heavy Photo Paper (their product # 02735-0), for INKJET

printers, made by International Paper Co, which I bought at a Staples store (They also have a website, at http://www.staples.

com). They also make a product called JetPrint "Multi-Project Paper, Gloss Finish", Medium Weight (their product # 07033-

0), which almost falls off the board by itself, after soaking for 10 minutes. Alas, it sometimes has pinholes. (I use an older

HP LaserJet 4. Your mileage may vary...)

However, the JetPrint "Multi-Project" paper *IS* PERFECT for doing the component side markings of circuit boards ("silk-

screening"), and anything else where etching isn't required, such as metal (or hard plastic?) instrument panels. And the Multi-

Project Paper is still available, as of 06/15/04. WalMart usually has it in stock.

THE BEST TONER-TRANSFER PAPER IS...

The very BEST paper I've found (basically PERFECT!) is sold as Staples "Picture Paper". It's available at Staples "office

supply" stores, in the USA. (And also from their website, at http://www.staples.com .) [I almost can't believe that I didn't try

that paper, before. It's one of the very FEW that I didn't try...!]

Below are the details, for buying the correct paper (at www.staples.com or at a Staples retail store). At the Staples website,

search for the "SKU" (item number). At a Staples store, ask an employee to help you find the Staples Picture paper with the

correct SKU. [Many thanks to Woody Eadie, for providing all of these details via email!]

Staples "Picture Paper" Details:

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Easy PCB (Printed Circuit Board) Fabrication, Using Laser Printer Toner ...IY at Home; Making, Homemade, Copper, Etch, Etching, Pattern, Electronic

30-sheet package:

Staples' SKU (Item Number) for the "Picture Paper" (30-sheet package): 471861

UPC barcode is: 7 18103 02238 5

Cost: $9.99 (30 sheets) at www.staples.com, as of 06/23/04.

100-sheet package:

Staples' SKU (Item Number) for the 100-sheet package is: 471865

UPC barcode is: 7 18103 02241 5

Cost: $29.99 (100 sheets) at www.staples.com, as of 06/23/04. (But I think I paid only

$19.99, at my local Staples store.)

With the Staples "Picture Paper", printing was absolutely perfect, even with long areas of very wide and very narrow traces.

I didn't even run them through the fuser twice, and still had excellent (perfect) results. This paper doesn't stick to the iron,

either. Press hard with the iron, for as long as you want (the more the better, it seems, with this paper; My boards actually

sometimes made a "sizzling" sound as they were dropped into the hot water.).

After the boards soak for 5 or 10 minutes, you can peel off at least one layer of paper and let them soak for another 10

minutes or more. The last layer of paper doesn't ever peel off in one piece. But that's OK! You can rub it almost as hard as

you want, with either your thumbs or a toothbrush, and you won't hurt the traces! [After I had made the first couple of boards

using the Staple paper, I started going to the toothbrush sooner. Mine was a soft (or maybe medium) stiffness brush. But I

could use circular or straight motions, pressing almost as hard as possible, with absolutely no noticeable damage to the

traces.]

Also, I have found that, in my old HP LaserJet 4 printer, it's much better if I use a genuine HP (Hewlett Packard) toner

cartridge, to get good results. The last time I bought a new toner cartridge, I bought the $75 "Staples"-brand "generic"

substitute cartridge, instead of the $88 genuine HP cartridge. The results were quite bad. The only difference that I can see is

that on the HP cartridge's box it says something about "microfine" toner particles. Maybe that's not just marketing hype, after

all. [NOTE that this was with the older type of paper (JetPrint). I have not yet tried a generic toner cartridge with the Staples

Picture Paper. - tpg, 06/16/04]

"For Inkjets" FAQ (10/2005): I've gotten quite a bit of email about the fact that the Staples paper I've recommended says

"For Inket Printers", on its packaging. Yes, it does. And no, I can't GUARANTEE that it won't turn your laser printer into a

piece of useless scrap. All I can say is that it hasn't seemed to hurt the old HP Laserjet 4 that I've been using it in, which I

also still use heavily for all of my other printing needs. "Your mileage may vary."

ETCHANT chemicals: I've only used Ferric Chloride, for etching. It may still be available aqt Radio Shack stores, in liquid

form, in pint (16 fl oz) bottles. It is also available from http://www.jameco.com, in powdered form. A single order of

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