Etch Copper Using a Laser Printer- PCB Making

Hi have a great day, in this instructables i'll explain the proccess i learned on college to create your own PCBs you can also use it to etch designs on cooper.

This method is the easier and cheaper for me as you dont need to use a photoresist film. If you are doing a PCB design you have to verify the printer did not resized your design, i had several problems printing it right. I used to print them on the university and they knew how to print it to the right size.

I created my design on eagle but you can make any kind of PCBs, I used to build guitar pedals from Tonepad (http://www.tonepad.com/projects.asp?projectType=fx)

PCB (or copper plate)

Design printed on coated paper using a laser printer (the paper from magazines)

Ferric chloride (50gr)

Steel Wool

Sandpaper

Acetone (i used nail enamel remover)

Scalpel and scissor (you can use a dremel or other tool to cut the PCB)

Iron

Needle

Tape

Rule

Sharpie

You have to make sure to print your design inverted as the toner will be transfered to the PCB. Use a laser printer and coated paper (You can use photo paper, but it is more messy on my opinion)

i used Libreoffice to edit the original PDF as eagle generates a document with only one design per page, and i wanted to print several designs in case the first failed. i copied the original design and organized four per page.

Cut your PCB a little bit more big than your design as it can move a little when we are stickying it, i leaved like half a centimeter more. I used the back of my scalpel as it is like an acrylic cutter, you can use a dremel to make it easier, Sand the edges nicely after cutted.

Now we will prepare the surface of the PCB as it have to be clean so the toner can stick properly to it. First use the steel wool to clean and make a rough surface and then use the acetone with a paper towel to clean the dust and grease, after this make sure not to touch it, take the board by the edges.

Cut your design from the sheet leaving a space to fold it arround the pcb (please check the photos).

Put your PCB already cutted, sanded and cleaned on top of your design and cover it, once you fix its position tape the edges of the paper arround the board so it can't move (we want it to stay in place as the toner can spread when heated)

Put a regular paper on top so the iron dont make direct contact with the coated paper. apply heat for arround 5 minutes, dont leave the iron on top for a long time as overheating it can damage the epoxy adhesive from the board. make sure to heat the corners and keep moving the iron. You can kind of see if the toner is transfered on the texture.

Don't try to peel the paper right away, wait for it to cool a little and dip it on water. wait at least 5 minutes and carefully take the paper from the board and clean the paper that still stick with your finger tips and water. use a needle to expose all the parts that still having fibers of the paper. (we just want to cover the design and leave the rest exposed so the compound can etch on it)

I added 50gr of ferric chloride to half a cup of water, add first the water as we dont want splash of the compound. mix it well by stirring it, once you mix them, it will warm a little.

Dip your pcb with the design on it on the ferric chloride and start stearing it (this will make the process way faster)
check your board each minute to see how is it going, it usually take arround five minutes. once you see your board fully etched take it out and rinse it with water to clean it

Now we have our design fully etched on the board, we just have to clean the toner to reveal the copper layout.

Use the acetone and steel wool to remove the toner and clean with a paper towel.

There you have it a nice and shiny copper design.