Custom PCB Boards?

[wvgca]

What is the file extension for a gerber file? Wondering if me CAD software a already can create one.

file extensions vary, used as extensions to denote top component, bottom solder, top and bottom silkscreen, top and bottom soldermask  , drill files...
most extension names are changable, and depend on the origional software, however they all ACT the same , just an ASCII vector file thats easily processed  ..
most prefexes are the board name , a generator will make all the files at once ..
there are multiple naming systems in place, but X2 and rS-274X are the most popular ..

[peteski]

For what the OP was asking (I think) was a way to clean up the resistors and there wiring.
I make my own with a cut off wheel in a Dremal. Solder SMT resistors to the small PC board and it really cleans up some wiring too. I get 4 resistors and wire tabs on less than a 1/2 inch X 1/2 inch board.

Here is another related thread (BTW, started by Russ himself).
https://www.therailwire.net/forum/index.php?topic=41340.0

[carlso]

Sir Pete,

did you mean to have the same link posted twice in above post?

carl

[wvgca]

if it matters, the same pcb software [i use eagle], can export to gcode for running a pcb mill,
in this case the top copper layer only

[peteski]

Sir Pete,

did you mean to have the same link posted twice in above post?

carl

Oops!  Fixed.  Thanks! I was fixing the old posts (replacing Photobucket photos with the ones I uploaded to TRW). and I got mixed up.

[Lemosteam]

Do any of these houses work with flexible PC board?

https://www.ebay.com/itm/Pyralux-Kapton-Flexible-Printed-Circuit-Board-Material-Various-Models-9-x-12/153153567548?var=453005815493

[wvgca]

Do any of these houses work with flexible PC board?

don't know, all that i've ordered was 1/16 and 1/32 thick rigid ..
you would have to go to their individual web pages , and see what types they do support ..

[C855B]

Do any of these houses work with flexible PC board?

https://www.ebay.com/itm/Pyralux-Kapton-Flexible-Printed-Circuit-Board-Material-Various-Models-9-x-12/153153567548?var=453005815493

Last year I priced flexible boards from a couple of prototype houses. They were very expensive, several hundred dollars for a single small board. Given the eBay pricing for the raw substrate it's apparently not the material, it's the setup and process. Or I wasn't finding the right place. The hobbyist-oriented shops like DirtyPCBs don't handle flex.

[Lemosteam]

I wonder if a laser would etch them and be able to create hole smaller that milled boards.

Anybody with a laser out there willing to try?

[DKS]

I wonder if a laser would etch them and be able to create hole smaller that milled boards.

Anybody with a laser out there willing to try?

I'd thought the same thing, so I consulted an expert. The problem is that it requires quite a powerful laser to etch metal, particularly because it's reflective, and the PC board material is also quite difficult to cut with a typical laser. Not to mention somewhat toxic--an exhaust system is an absolute must.

[Lemosteam]

I'd thought the same thing, so I consulted an expert. The problem is that it requires quite a powerful laser to etch metal, particularly because it's reflective, and the PC board material is also quite difficult to cut with a typical laser. Not to mention somewhat toxic--an exhaust system is an absolute must.

Was thing this strictly for the flexible, single sided PCB material.  Is that what you asked about?

[DKS]

Was thing this strictly for the flexible, single sided PCB material.  Is that what you asked about?

No, just regular board. But the problem regarding copper is probably still similar. Maybe. Dunno.

[wvgca]

a one watt laser in a special build doesn't have enough power to remove copper even one ounce thickness  ...
i have tried on several occasions with a modified plotter version ..
but it will remove dark coloured resist fairly well, and allow etching by normal liquid immersion methods .

you would -probably- need twenty watts as a minimum for removal of copper

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[Lemosteam]

a one watt laser in a special build doesn't have enough power to remove copper even one ounce thickness  ...
i have tried on several occasions with a modified plotter version ..
but it will remove dark coloured resist fairly well, and allow etching by normal liquid immersion methods .

you would -probably- need twenty watts as a minimum for removal of copper

(Attachment Link)

Thanks, I think that settles it.  So one would apply the resist to the entire surface and then laser away the traces for chemical enchant to do the work.  Would there be a way to realign the workipiect to, after etching, run the laser a second time to cut out the parts and make any necessary holes through the parent backing material?

Does the laser zero out to a coo on location after runs??

In other words, could one make a three or four pin plate fixture to return the material to the same location for mutliple laser runs?

[wvgca]

In other words, could one make a three or four pin plate fixture to return the material to the same location for mutliple laser runs?

most commercial units have index pins, and laser jobs are very repeatable ..
mine is home made, and does not, the limit switches are -sometimes- close, lol  ..
i have used mine just to remove etch resist, plus cut wood slowly for decks and such  ..
a change of 50 thousands in height changes the beam spot quite  bit ..