How Does Clone PCB Work and its Benefits

What is Cloning PCB?

Cloning PCB, also known as PCB duplication, involves creating a copy of an original printed circuit board (PCB) using reverse engineering methods. This process allows you to replicate the exact design of a PCB without the need to undergo a laborious design process. It is particularly useful when you need to produce multiple versions of the same PCB, create new products using an existing design, or reuse components from a previous project. If you’re new to electronics and unfamiliar with PCB cloning, this guide will provide essential information on how to effectively clone printed circuit boards.

Why You Need Cloning PCB Services

Cloning PCB is a cost-effective solution for producing multiple copies during the PCB manufacturing process. Whether you need several boards for product testing, sample boards for customers, or preparation for mass production, cloning PCB allows you to efficiently generate the required number of boards with minimal effort. Additionally, if you have an outdated design that’s no longer available, cloning PCB helps you recreate new boards from the old design. Benefits of our PCB cloning service include:

• Making modifications or improvements to the original design
• Creating multiple copies for mass production
• Producing an identical copy of an existing electronic product
• Adapting an existing PCB design with modifications
• Developing a PCB from a design
• Creating a backup if the original is lost or damaged
• Testing a design before full-scale manufacturing
• Repairing damaged tracks
• Replacing missing electronic components

Additional Benefits:

• Optimizes Time and Cost: Cloning PCB is more efficient compared to traditional PCB manufacturing, saving both time and money. You avoid the lengthy design process and reduce costs related to PCB testing and prototyping, as the original design is already established.

• Simplifies Production: The production process becomes more straightforward as manufacturers can reverse engineer innovative designs. The automated cloning process streamlines production, automating manufacturing processes and saving on manual labor costs. This leads to the production of high-performance, long-lasting boards.

• Improved Scalability and Freedom: Cloning PCB offers flexibility to adapt throughout the manufacturing process and to produce boards that meet consumer needs. It also supports scalability, allowing a large number of boards to be manufactured from a single design.

• Building Customer-Friendly Products: Engineers can build products that cater to customer preferences by reverse engineering effective PCB designs.

• Offers Production Flexibility: A single PCB design can be used to mass manufacture products, providing flexibility in production.

• Consistency in Performance: Cloned boards maintain consistency in performance, as the design has been tried and tested.

• Improves Timelines: PCB cloning significantly reduces the time-to-market, providing a competitive edge through its simplicity and speed.

How to Clone a PCB

Several methods are available for cloning a PCB, each with unique benefits and challenges. Understanding these methods and their potential issues is crucial for making an informed choice and achieving the desired outcome. Generally, the PCB cloning process involves the following steps:

#1 – IC Unlock (Decryption)
Extract the program from the board if it is locked.

#2 – PCB Reverse Engineering
Obtain the Gerber files and BOM list, create the layout, and convert it into a schematic.

#3 – Prototype PCB Fabrication
Produce a sample PCB based on the schematic.

#4 – PCB Functional Testing
Evaluate the performance of the new board, troubleshoot issues, and resolve any incompatibilities before proceeding to mass production.

Tips:

• For #1, IC unlock is only necessary if the program is protected.
• For #2, reverse engineering is crucial for obtaining the BOM and schematic diagrams.

Required Tools and Equipment:

• Computer
• AUTOCAD
• Scanner
• PROTEL

Step-by-Step Cloning Process:

1. Scan the Original PCB
   Place the original PCB in a scanner and adjust contrast and brightness settings.
2. Open AUTOCAD and Create a File
   Start AUTOCAD, create a new file, and insert raster images of the PCB. Draw a rectangular frame around the PCB and use object lock points for accurate alignment.
3. Draw Component Packages and Shapes
   Design the board by calculating the required quantity. Each package should include one board drawing. Use PROTEL99 to generate component packages and shapes.
4. Import CAD Files into PROTEL99
   Open PROTEL99 PCB editor, select ‘import CAD file’ from the menu, and import the CAD file. You will see the component packaging graph in the PROTEL99 editor.
5. Create PCB Component Editor
   Use PROTEL99’s PCB component editor to open another instance and place components.
6. Send Component Packages to CAD File
   After creating component packages in PROTEL99, export each to a CAD file.
7. Copy the Component Package to the CAD File
   Duplicate the PCB image into the imported CAD file by copying the component packages. Open both CAD files for this task.
8. Add Vias and Pads
   Measure the diameters of the pads and vias, then use the Circle sub-item from the drawing menu to place them accurately. Ensure proper placement and filling in the CAD file.
9. Draw Traces and Add Silkscreen
   Use the Drawing menu to select line aggregates and add the silkscreen. For irregular screens, use the polymer line tool.

Conclusion

Cloning PCB is a complex but valuable process in the electronics industry, offering benefits such as the reproduction of obsolete components, troubleshooting of faulty designs, and product improvement. However, it also comes with challenges, including the complexity of reverse engineering and legal considerations. By following a systematic approach and using the right tools and techniques, engineers can successfully clone PCBs and achieve their desired outcomes.