DIY Fiberglass PCB Strata Construction

Here is a quick pictorial on DIY PCBs. Once the materials are collected the laminating and clamping process takes less than twenty minutes.

Double waxed paper on flat surface. Some coat it with cooking spray but I haven't found it necessary.




For this project I used both woven and bulk pad fabric.






Flow an spread some of the resin/hardener mixture on the core. Don't try to make it too uniform on this step as the mat will pull apart and make uneven clogs.



Cover that with a second layer of the woven fabric. Distribute the remainder on the mixture and smooth out with a flat tool. Try to get an even amount on the entire sandwich.




You don't have to be perfect as the next step helps the distribution.




Cover the entire sandwich with another piece of waxed paper and then the top clamping plate.




If you have long reach clamps, start in the middle and work out. If you don't own clamps just place something very heavy on the top - apiece of plywood or metal, a ceramic tile or for perfectionists - a square of marble/granite flooring from your local home improvement store.



After 2 -6 hours, depending how you mixed the resin and hardner - and the thickness - this is what you get.



A little trimming (did mine on an old tile saw) and a uniform, strong product is ready for final smoothing (optional) and sizing. These are 7.5" X 7" and 1.75" X 10".




The thickness can be adjusted by using the desired amount of the matt fabric if you have it. The auto parts stores carry a variety of kits that may or may not include the matting. Several layers of the woven stuff also works well .





In the next days I'll continue with the sizing, drilling and finishing of an example PS project,