PCB Manufacturing Process at AIVON
1. PCB Design
The manufacturing process begins with PCB design, typically created by professional designers using software such as Altium Designer or similar tools.
This design serves as the blueprint for production.
Most customers design their own PCBs and submit the Gerber files—the industry-standard open vector file format—for fabrication.
2. Inspection and DFM Review
After AIVON receives the PCB design files, our engineers perform a thorough Design for Manufacturability (DFM) review.
During this step, key parameters such as trace width, spacing, hole size, and layer alignment are verified to ensure full compliance with AIVON’s manufacturing capabilities.
Once approved, multiple copies of the same design are panelized on a larger sheet to optimize cost, efficiency, and production speed.
3. Cleaning and Cutting
After design verification, the raw PCB panels are cleaned to remove any surface contaminants that could affect production quality.
They are then cut into smaller panels suitable for subsequent process steps using precision cutting machines.
4. Drilling
Drilling is performed to create holes for through-hole components and interlayer connections.
The PCB panel is fixed on an MDF backing board with an aluminum entry sheet to ensure clean, burr-free holes.
Computer-controlled drilling machines execute the process with high accuracy, and edges are smoothed afterward to ensure uniformity.
5. Electroplating
To establish electrical connections between copper layers, the drilled holes are plated with copper.
Panels are immersed in an electrolytic bath, where copper ions deposit inside the holes under computer-controlled conditions, creating reliable interlayer connections.
6. Printing
A photoresist film containing the circuit pattern is precisely aligned with the PCB panel.
Using a UV exposure printer, the circuit design is transferred onto the board.
Afterward, chemical developers remove unexposed areas, leaving only the intended circuit pattern.
7. Etching
The etching process removes unwanted copper from the panel using a specialized alkaline solution.
This step defines the actual copper traces on the board.
After etching, panels are thoroughly cleaned to remove all residual chemicals.
8. Automated Optical Inspection (AOI)
Each etched panel undergoes automated optical inspection using computer vision technology to detect any trace breaks, shorts, or pattern errors.
This ensures all boards meet AIVON’s stringent quality standards before continuing.
9. Solder Mask Application
A layer of epoxy solder mask is applied to both sides of the PCB to protect copper surfaces and prevent solder bridges during assembly.
After application, panels are baked to cure and firmly secure the solder mask.
10. Surface Finish
Surface finishes protect exposed copper and ensure reliable soldering.
Common finishes include HASL, ENIG (Immersion Gold), Hard Gold, and OSP (Organic Solderability Preservative).
AIVON selects the appropriate finish based on the board’s design and application.
11. Electrical Testing
All circuits on the board undergo automated electrical testing to verify that connections match the original design and there are no open or short circuits.
This step guarantees the functional integrity of every PCB.
12. Milling and Final Processing
The final step involves CNC milling to separate individual boards from the production panel.
After milling, PCBs are cleaned, dried, vacuum-sealed, and bubble-wrapped to prevent dust and moisture exposure.
The finished boards are then carefully packaged and shipped to the customer.
AIVON’s rigorous process ensures every PCB is produced with precision, consistency, and reliability, meeting the highest global manufacturing standards.
