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Hands-On PCB Design Workshop: From Schematic to Fabrication

A Printed Circuit Board (PCB) is the foundation of almost every electronic device. While breadboard prototyping is great for learning, real-world products use custom PCBs that are compact, reliable, and manufacturable at scale. Learning PCB design is an essential skill for any electronics engineer.

This workshop takes participants from zero PCB knowledge to designing and ordering their own custom boards.

Workshop Overview

Day 1: PCB fundamentals and schematic design
Day 2: PCB layout and routing
Day 3: Design for manufacturing and Gerber generation
Day 4: Assembly and testing
Day 5: Project showcase

Day 1: PCB Fundamentals

What is a PCB?

A PCB mechanically supports and electrically connects components using conductive traces, pads, and vias etched onto copper layers laminated on a non-conductive substrate (typically FR4 fiberglass).

Key Terminology

• Trace — Copper path that carries electrical signals.
• Pad — Exposed copper area where components are soldered.
• Via — Plated hole connecting traces on different layers.
• Silkscreen — White text and outlines printed on the board for component identification.
• Solder mask — Green (or other color) protective layer covering copper traces.
• Gerber file — Standard file format used for PCB manufacturing.

Choosing a PCB Design Tool

We recommend these tools for beginners and professionals:

EasyEDA — Free, browser-based, integrated component library,
           great for beginners. Direct JLCPCB ordering.

KiCad — Open source, professional-grade, no restrictions.
        Steeper learning curve but industry respect.

Altium Designer — Industry standard. Expensive but used
                  by most professional PCB design houses.

Day 2: Schematic Design

The schematic is the logical representation of your circuit. Every connection between components must be clearly defined.

Project: RGB LED Controller

Students design a simple RGB LED controller circuit using an Arduino Nano, three MOSFETs, and an RGB LED strip:

Schematic Bill of Materials:
1 × Arduino Nano
3 × IRF520 N-channel MOSFET
1 × RGB LED strip (common anode)
3 × 10kΩ resistors (gate pull-down)
1 × 12V DC power supply
1 × 100µF capacitor (power filtering)
1 × Push button (mode select)
1 × 10kΩ resistor (button pull-up)

Schematic Design Steps

1. Create a new project in EasyEDA.
2. Add components from the library — search by part number.
3. Connect pins using the wire tool — match logical connections.
4. Use net labels for complex connections instead of crossing wires.
5. Add power and ground ports to every IC.
6. Run electrical rules check (ERC) to verify no unconnected pins.
7. Add component values and designators.

Day 3: PCB Layout and Routing

This is where the schematic becomes a physical board. Students learn placement, routing, and design rules.

Component Placement Guidelines

• Place connectors at the board edge for easy access.
• Keep power components (MOSFETs, voltage regulators) away from sensitive analog circuits.
• Place decoupling capacitors as close as possible to IC power pins.
• Group related components together (e.g., all RGB LED driver components in one area).
• Orient all ICs in the same direction for easier soldering and troubleshooting.

Routing Guidelines

• Use 45-degree or 90-degree traces (no sharp angles in professional boards).
• Power traces should be wider than signal traces — at least 0.5mm for low power, 1-2mm for high current.
• Keep high-speed signals short and direct.
• Avoid 90-degree corners — use 45-degree miters to reduce signal reflection.
• Add ground pours (copper fill) on both layers for noise reduction and heat dissipation.

Trace Width Guidelines (1oz copper):
Signal (digital/analog):   0.25mm — 0.5mm (10-20 mil)
Power (low current):       0.5mm — 1.0mm (20-40 mil)
Power (high current):      1.0mm — 2.0mm+ (40-80 mil)
1A current:                ~0.5mm width
3A current:                ~1.5mm width

Design Rule Check (DRC)

Before finalizing, run DRC to catch manufacturing issues:

Minimum Clearance:  0.2mm (8 mil)
Minimum Trace:      0.25mm (10 mil)
Minimum Hole Size:  0.3mm (12 mil)
Minimum Annular Ring: 0.15mm (6 mil)

Day 4: Gerber Generation and Ordering

Gerber files are the industry-standard format that PCB manufacturers use to fabricate boards.

Generating Gerbers

1. In EasyEDA, go to Fabrication > Generate Gerber.
2. Select layers: Top Layer, Bottom Layer, Top Solder Mask, Bottom Solder Mask, Top Silkscreen, Bottom Silkscreen, Drill File.
3. Set output format: RS-274X (standard Gerber).
4. Generate and download the ZIP file.

Gerber File Checklist

Required files for PCB manufacturing:
.GTL — Top copper layer
.GBL — Bottom copper layer
.GTS — Top solder mask
.GBS — Bottom solder mask
.GTO — Top silkscreen
.GBO — Bottom silkscreen
.GKO — Board outline
.TXT — Drill file (NC Drill)
.GTP — Top paste (for SMT assembly, optional)

Ordering from Manufacturers

Students learn to order from popular PCB manufacturers:

JLCPCB (China):
- 5 boards, 2-layer: ~$2 + shipping
- 5-7 day turnaround
- Free shipping coupon often available

PCBWay (China):
- Higher quality, more options
- 3D printing and assembly available
- 10 boards, 2-layer: ~$5 + shipping

Robu.in (India):
- Local manufacturing, faster delivery
- 10 boards, 2-layer: ~Rs. 500-800
- Supports Indian electronics community

Day 5: Assembly and Testing

Soldering Techniques

Students learn through-hole and SMD soldering:

• Setting up the soldering station — temperature 330C for leaded solder, 360C for lead-free.
• Through-hole soldering — heat pad and pin simultaneously, apply solder, let cool naturally.
• SMD soldering — apply solder paste, place components with tweezers, hot air reflow.
• Inspection — check for solder bridges, cold joints, and missing connections.

Testing and Troubleshooting

• Visual inspection under magnification — check all joints.
• Continuity test with multimeter — verify power and ground are not shorted before applying power.
• Power-up test — apply power and check voltage at each IC power pin.
• Functional test — program the Arduino Nano and test each LED channel.

Common PCB Defects

Defect                   Cause                    Fix
Solder bridge            Excess solder            Use desoldering wick
Cold joint               Insufficient heat        Reheat with fresh solder
Component reversed       Wrong orientation        Desolder and reorient
Trace lifted             Excessive heat           Use lower iron temperature
Missing via              Broken inner layer       Jumper wire as workaround
Pad lifted               Mechanical stress        Use nearby via as alternative
Solder ball              Spattered solder         Clean with flux and wick

Projects Students Designed in This Workshop

• RGB LED Controller — Arduino Nano + MOSFETs for controlling RGB strips with PWM.
• Temperature Logger — DS18B20 sensor + SD card module + Arduino Pro Mini.
• Motor Driver Board — L298N-based dual H-bridge for robot control.
• Power Supply Board — 12V to 5V/3.3V regulated output with multiple connectors.
• Sensor Hub — Breakout board connecting DHT11, ultrasonic, and PIR sensors to a single connector.

PCB Design Checklist for Beginners

Before submitting for manufacturing, verify:
- Schematic passes ERC (Electrical Rules Check)
- PCB passes DRC (Design Rules Check)
- All footprints match actual components
- Component values are clearly marked on silkscreen
- Board outline is correct size and shape
- Mounting holes are included
- All vias have proper annular ring
- No overlapping tracks or vias
- Copper pour is connected to correct net
- Gerber files are complete and named correctly
- Drill file includes all holes
- Board stackup is specified (2-layer, 4-layer, etc.)
- Copper weight is selected (1oz is standard)

Conclusion

PCB design is a skill that separates hobbyists from professional engineers. Moving from breadboard to custom PCB opens the door to building reliable, compact, and manufacturable electronic products.

This workshop gives students the complete pipeline — from drawing a schematic to holding a finished, soldered board in their hands. It's a transformative experience that builds confidence and provides a genuinely useful skill for any electronics career.