Electronics Manufacturing, Guide, PCB Manufacturing

Double Sided PCB: Advantages, Applications and Manufacturing Process

Double sided PCB

What is a Double Sided PCB?

A double-sided PCB  is a printed circuit board that has two copper layers on top and bottom sides. So copper pads and copper traces are available on both sides of the PCB, and the two copper layers are connected by plated through holes. Inner layers are not present in double-sided PCBs.

A double-sided PCB offers a low-cost solution to the customer for their electronic devices. In a double-sided PCB, components can be placed on only one side or both sides. We can create complexity as per our design on a double-sided PCB.

Different Types of Double Sided PCB

  • Rigid Double-sided PCB: This is the most common double-sided PCB. It is usually made of FR4 material which is the best option for high electrical properties and low cost.
  • Flexible Double-sided PCB: It is usually made of polyimide material usually, with excellent flexibility and is also cost-effective. It is widely used in electronics that need lightweight.
  • Flex-Rigid Double Sided PCB: This board is a finished circuit board that combines rigid printed circuit boards and flexible printed circuit boards and has the characteristics of both flexibility and rigidity.
  • Metal Core Double-Sided PCB: The substrate of this board is made of copper, aluminum and other metal materials, so it has better heat dissipation and is usually suitable for the LED industry.

Advantages of Double Sided PCBs

  • Low Cost: Double sided PCB is a low-cost solution for the double sided PCB fabrication. And a double sided PCB board optimizes the board size at a low cost.
  • Easy to Produce: Double sided PCB board are much easier to produce comparing multilayer PCBs since the inner layer and lamination is not needed.
  • Better Working Performance than Single-layer Boards: Sometimes, a double-sided PCB works as a single sided PCB. so, it would be better than constructing the single side PCB.
  • Flexibility: Most of the customers prefer double sided PCB due to its flexibility of use, it is the most widely used printed circuit boards.

Applications of Double Sided PCBs

  • Consumer Electronics: Double sided PCBs are widely used in consumer electronics due to their low cost. Such as  televisions, game consoles, digital cameras, audio devices,  printer and fax machines, home appliances.
  • Power Supply Industry: Double sided PCBs have easy construction for the placement of parts, so it is used in LED boards, power supply circuits, relay circuits, power converter circuits, etc.
  • Automotive: In the automotive industry, double-sided PCBs are used in vehicle control systems, engine management systems and other automotive applications. They are heat resistant and can adapt to temperature changes typical in automotive environments.
  • Telecommunications: Double-sided PCBs are crucial in telecommunications infrastructure, including routers, switches, and networking devices. They support high-speed data transfer and signal processing, making them essential in telecommunications systems.
  • Medical Devices: Medical equipment relies on double-sided PCBs for applications such as patient monitoring systems, diagnostic equipment and other medical instruments. These boards ensure reliable performance and precise control in healthcare settings.

Double Sided PCB Manufacturing Process

  • DFM Check: DFM is the verification process for manufacturing the boards. In this process, the DFM engineer verifies the copper, mask, silkscreen, and drill using particular software and provides information on the issues related to the double sided PCB fabrication process. If the fabrication design has issues, then it provides the DFM report to the customer. The DFM report includes all manufacturing-related issues, fabrication specifications, hole sizes, trace-to-trace spacing, trace to pad spacing, pad to pad spacing, pad size, blind via size, buried via size, via-fill, etc. So, it’s beneficial for all of us to know if our design has issues or not, and it would be easy for the production floor.
  • Penalization Process on the Software: The penalization process is used to determine how many ups are set in our standard panel for production use. Then it gets different penalization outputs like core scaling, maskless output, plot output, drill output, and etch testing. After all outputs, these raw data are going to the production floor to make boards according to this raw data.
  • Panel Cutting: Firstly, material arrived at the production house from inventory as big sheet like 41*49’’. So we need to cut PCB material according to our board thickness requirement. Most vendors use FR4 and 370HR material for standard double-sided PCBs due to their very low cost.
  • Drilling: In this stage, the PCB was fixed with fixtures to get exact drilling. After that, the drilling program was loaded into the drilling machine, and that drilling machine drilled the holes according to the PCB drill layer. Sometimes via fill, blind vias, and buried vias are needed. At that time, drilling was done according to the special process.
  • Copper Plating: The production floor has one large bath for copper plating. Copper plating is applied to PCB surfaces. So, it creates the board thickness and provides copper connections to the layers with surface pads. The PCB board has been drilled for connection from layer to layer. Copper plating makes the PCB robust.

Double sided PCB board

  • Imaging Outer Layers: Image transfer is one type of method to place circuitry images on copper using films. For image transfer scrubbing, dry film with protective film is required. Also, oxidation was not allowed on the surface. So please make sure the PCB is neat and clean. After scrubbing, circuitry film was applied to the PCB. Please make sure film registration was accurately placed; otherwise, it creates shorts and broken errors.
  • Quality Inspection of Outer Layers: After the outer layer image transfer, we need to check and inspect the image for proper registration of the outer layers. Mainly, this stage verifies short circuits, broken connections, and misalignment of the image. If the image transfer was not successful, then it needs more time to reconstruct them. AOI is used to check the above-mentioned errors and register layers. AOI is making many cameras on the machine to capture the images. So we can compare the original image to the latest manufactured image.
  • Etching: This stage removed unnecessary copper from the PCB. Once etching is done, circuitry images remain present on the PCB. Normally, etching is done with chemical solvents. As we know, we need only copper features on the PCB, so etching is the best solution to make copper features visible properly.
  • Masking: A solder mask was applied to the copper layers. So, these solder mask openings were used for soldering at those locations only. Mostly, alumina PCB has a white solder mask color due to its use in lighting, etc. Also, we need to make sure Solder masking printing is done accurately; otherwise, it creates gang mask outfits, shorts, etc.
  • Legend Printing: After solder mask printing, silkscreen was applied to the PCB. It identifies the component reference designators, their polarity, part number, revision of boards, etc. We need some clearance from the mask for silkscreen printing.
  • Surface Finish: Surface finish plays the most crucial role in the PCB manufacturing process. The surface finish is used for protection from oxidation and also as a proper soldering surface for the PCB and its components. There are many surface finishes available on the PCB market, like OSP, ENIG, HASL, gold body, etc.
  • Routing and Scoring: After that, the routing and scoring program is loaded into the routing and scoring machine to depanelize or penalize the boards. Mostly, Alumina PCBs are the preferred routing methods for panelize or depanelize. But if some square boards come, then the score is most suitable to penalize them.

 

China double sided PCB

  • Final QA: After the whole manufacturing process is done, boards are returned to the final QA team to be inspected with different inspection methods like flying probe tests, high-precision tests, etc., so the PCB is created and anything that needs to be done can be done at this stage. The final QA team also confirms if additional requirements are needed, like a TDR report.

 

  • Packaging: The shipping team attached the whole document of the PCB with the packaging of the boards. The shipping team packs the boards with depanelized or panelized boards according to the requirements. And also add markings and labels regarding PCB boards. And ship the boards to the particular address via FedEx and other delivery methods.

 

Double sided PCB fabrication

What are the Advantages of Double Sided PCB Services Provided by Viasion?

Although most PCB manufacturers have mastered the double sided PCB manufacturing process, there is still a large gap between the double sided PCB manufacturers in terms of product quality, price, etc. How to choose an excellent double sided PCB manufacturer? This requires considering many factors, including business experience, technology, personnel, qualifications, reputation, etc. Speaking of which, you may wish to consider China double sided PCB manufacturers. Among them, Viasion is a China double sided PCB manufacturer with over 16 years of experience. Choosing us has the following benefits:

  • Advanced equipment and technology
  • Intimate exclusive service
  • Full process contracting service
  • No order quantity limit
  • High product quality assurance

In addition, we have many benefits. We have a professional customer service team and technical staff waiting for your consultation at any time. We hope to establish long-term cooperation with you.

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