[XCSSA] LaserJet printer transfers for PCB etching

[X-otic Computer Systems of San Antonio]

On Friday 22 May 2009 11:52:28 am X-otic Computer Systems of San Antonio 
wrote:
> Good Morning:
>
> I got to thinking about the laser printer method for transferring
> toner to copper clad for etching.
>
> Assuming single-side PCBs, can you share with me your experiences with
> doing it?
>
> From what I understand, you print the PCB layout out and then iron it
> on the copper clad using a clothing iron.. 

Yup.

I know that at least 2-3 people (including myself) have used toner/iron based 
transfer masking for copper board etching.  Some folks have had better 
results than others.  

Personally, I never had great toner/iron results using 0.1" DIP layouts via 
toner transfer and ferrochloric acid (etching). It seemed that the toner 
always either cracked, chipped off (requiring touch ups or extra solder 
work).  But some folks on list have had better results. Here's an example 
overview of how it's done:
	http://mossycup.com/node/15


Some folks also say that they get great toner xfer result with this glossy 
paper from Staples:
	
http://www.staples.com/office/supplies/p4_Staples-Photo-Basic-Paper-8-1-2-x-11-Gloss-50-Pack_274671_Business_Supplies_2_10054_FEATURED:SC11SC1
	http://www.fullnet.com/~tomg/gooteepc.htm

Lots of other good info here:
	http://www.fullnet.com/~tomg/gooteepc.htm

and in the Yahoo groups "Homebrew_PCBs".


One alternate method to just using toner is to use the "blue paper" stuff, 
called press-n-peel, which has much fewer problems with the afore mentioned 
pure toner/paper methods.  Here's a link to press-n-peel:
	http://www.elexp.com/pro_npb5.htm
	http://eegeek.net/content/view/34/31/

It's a bit more expensive than the paper or glossy method.. but has better 
results.



> What I am thinking is 
> about using a fuser cartridge (with small adjustments for the clad)
> from a laser printer that is heated up via the quartz light that runs
> through it and then sending the clad and the paper through it once the
> fuser is hot.
[...]
> What are your thoughts on this?  Google research turned up nothing and
> I can't be the first person to think of this.  Your ideas,
> suggestions, etc?


Hmm.. I don't think that would work.
You could try it.. but copper is such a great conductor of heat that you would 
either have to seriously jack up the temperature to get the same quality of 
toner fusion.  I know that even when you're just fusing it to the copper with 
the iron.. you really have to do it hot.  So hot that it browns the paper.

If you're interested in an automated way of putting etch resist directly onto 
the copper, check this out.  This guy modified an ink jet print assembly to 
kind of doing what you're thinking about:
	http://techref.massmind.org/techref/pcb/etch/directinkjetresist.htm

If I were you.. before trashing a laser printer.. try the standard iron 
method.. the iron/blue press-n-peel stuff.. or even the ink jet method.

Let us know what you find.

Tweeks
p.s. several of us have stopped messing home brew etching and now use 
commercial PCB vendors.. Some will do a board (or a matrix of little boards) 
for as little as $30. And they end up looking like this:
	http://theweeks.org/tmp/SHOW/2_b_demux-pop1-rear_l.jpg