PCB MANUFACTURING INTERNSHIP

An Internship report submitted in partial fulfilment of the requirement of

degree of

BACHELOR OF TECHNOLOGY

In

ELECTRONCIS AND COMMUNICATION ENGINEERING

Submitted

By

AMAN PATEL

SYSTEM ID: 2023589343

Under the guidance of

MR. RAJAT AGGARWAL

Senior Engineer at

S.K. DENT INDIA

DEPARTMENT OF ELECTRICAL ELECTRONICS AND

COMMUNICATION ENGINEERING

SHARDA UNIVERSITY, GREATER NOIDA (2024- 2025)

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TRAINING COMPLETION CERTIFICATE

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 DECLARATION
I hereby declare that the Industrial Training Report entitled “PCB Manufacturing” is an authentic
record of my own work as requirements of 4-Weeks Industrial Training during the period from
12.06.2024 to 12.07.2024 for the award of degree of Bachelor of Technology in Electronics and
Communication Engineering, School of Engineering and Technology, Sharda University,
Greater Noida.

Date:

AMAN PATEL

2022472505

Certified that the above statement made by the student is correct to the best of our knowledge
and belief.

Examined by: Head of Department

Ms.Ritu Singh Prof. Pratima Walde

Assistant Professor (Department of EECE,SSET)

(Department of EECE,SSET)

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 ACKNOWLEGEMENT
I would like to express my heartfelt gratitude to everyone who contributed to making my
internship at S.K. Dent India an enriching experience.
First and foremost, I extend my sincere thanks to my supervisor and the entire mentoring
team at S.K. Dent India for their invaluable guidance and support throughout my
internship. Their patience and willingness to share their expertise greatly enhanced my
learning experience. The constructive feedback and insights they provided helped me
navigate the complexities of the production line, further developing my technical and
professional skills. A special note of appreciation goes to the production team, whose
collaboration and assistance were crucial in helping me understand the various stages of
modem manufacturing and the rigorous quality control processes involved. Their
willingness to explain each step, answer my questions, and involve me in hands-on tasks
made my internship both educational and enjoyable.
I would also like to thank Sharda University for facilitating this internship opportunity.
Their support in connecting me with S.K. Dent India has allowed me to gain practical
experience, which I believe will be instrumental in my future career.
Lastly, I am grateful to my friends and family for their encouragement and understanding
throughout this period, as their support kept me motivated and focused on my goals.

AMANPATEL
2023589343

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 LIST OF CONTENTS

TITLE PAGE No.

TRAINING CERTIFICATE i

DECLARATION ii

ACKNOWLEDGEMENT iii

LIST OF CONTENTS v

CHAPTER 1- INTRODUCTION TO PCB COMPONENTS

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1.1 Category of PCB Components

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1.2 Mounting Technology 3

CHAPTER 2- PCB DESIGNING 4

2.1 Key Steps In PCB Designing 5

2.2 Goals of PCB Designing 8

2.3 Softwares for PCB Designing 12

CHAPTER 3- PCB PROGRAMMING 24

3.1 Key Concepts in Basic PCB Programming 24

CHAPTER 4- PCB COMPONENTS MOUNTING

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4.1 Types of Mounting Techniques

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4.2 Key Process of Component Mounting

4.3 Importance of Component Mounting

CHAPTER 5-PCB TESTING 31

5.1 Introduction To PCB Testing

5.2 Importance of PCB Testing

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CHAPTER 6- CONCLUSION

CHAPTER 1 INTRODUCTION TO PCB COMPONENTS

Introduction to PCB Components

PCB (Printed Circuit Board) components are the building blocks of electronic circuits. They are
mounted on the PCB to perform specific electrical functions, such as controlling current,
processing signals, and storing data. These components are connected via copper traces on the
PCB to form a complete electronic system.

Categories of PCB Components:

1. Passive Components:

o Resistors: Control the flow of current by providing resistance.

o Capacitors: Store and release electrical energy, often used for filtering and
smoothing voltage.

o Inductors: Store energy in a magnetic field, commonly used in power supplies

and filters.

2. Active Components:

o Transistors: Act as switches or amplifiers for electronic signals.

o Diodes: Allow current to flow in one direction, protecting circuits from reverse
polarity.

o Integrated Circuits (ICs): Miniaturized circuits that perform complex functions

like processing, memory, or power regulation.

3. Electromechanical Components:

o Switches: Enable or disable the flow of current manually.

o Relays: Electrically controlled switches for high-power circuits.

o Connectors: Provide interfaces for external connections, such as USB or HDMI.

4. Power Components:

o Batteries: Store and supply energy to the circuit.

o Voltage Regulators: Ensure stable voltage levels for the components.

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 5. Specialized Components:

o Sensors: Detect physical changes like temperature, light, or motion.

o LEDs: Emit light as indicators or for illumination.

o Oscillators: Generate clock signals for timing purposes in circuits.

Mounting Technologies:

 Through-Hole Components: Mounted by inserting leads into drilled holes, providing

strong mechanical bonds.

 Surface Mount Components (SMD): Mounted directly onto the PCB surface, enabling
compact and high-density designs.

Importance of PCB Components:

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 CHAPTER 2 PCB DESIGNING
PCB Designing Overview

PCB (Printed Circuit Board) designing is the process of creating a detailed layout that defines the
electrical connections and physical arrangement of components on a circuit board. It bridges the
gap between an electronic circuit's schematic and its physical implementation, ensuring
functionality, reliability, and manufacturability.

Key Steps in PCB Designing:

1. Schematic Design:
A schematic is created using Electronic Design Automation (EDA) tools like KiCad,
Eagle, or Altium Designer. It represents the circuit's electrical connections using symbols
for components.

2. Component Selection:
Components such as resistors, capacitors, ICs, and connectors are chosen based on the
schematic requirements and specifications.

3. Footprint Creation:
Each component's physical layout (footprint) is designed to match its actual size, shape,
and pin configuration for placement on the board.

4. Board Outline and Layer Configuration:

The PCB's size, shape, and the number of layers (single, double, or multilayer) are
defined based on the application and complexity.

5. Placement of Components:
Components are arranged on the board with consideration for space, functionality, and
design rules such as thermal management and signal integrity.

6. Routing:
Electrical connections are created as traces on the PCB. Routing follows design rules for
trace width, spacing, and via usage to ensure electrical performance and
manufacturability.

7. Design Rule Check (DRC):

Automated checks ensure the design meets electrical and manufacturing constraints, such
as trace clearances and hole sizes.

8. Generating Gerber Files:

The finalized design is converted into Gerber files, which are standard formats used by
PCB manufacturers to produce the board.

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Goals of PCB Designing:

 Optimize space usage.

 Minimize signal interference and cross-talk.

 Ensure thermal efficiency and mechanical stability.

 Simplify manufacturing and assembly.

Softwares for PCB Designing:

 KiCad (open-source)

 Protrace

 Altium Designer

 EasyEDA (web-based)

PCB designing plays a crucial role in modern electronics, enabling efficient and scalable
development of devices across various industries.

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 CHAPTER 3 PCB PROGRAMMING BASICS
Introduction to Basic PCB Programming

PCB programming refers to writing and uploading code to a microcontroller or programmable IC

(Integrated Circuit) embedded on a PCB. This process enables the PCB to perform specific
functions, control devices, or interact with other hardware components.

Key Concepts in Basic PCB Programming:

1. Microcontroller or Microprocessor:

o A microcontroller (e.g., Arduino, STM32) or microprocessor is the "brain" of the

PCB that executes the program.

o These chips are programmed to control other components like LEDs, sensors,
motors, and more.

2. Programming Languages:

o Common languages for PCB programming include:

 C/C++: Widely used for embedded systems and microcontrollers.

 Python: Popular for high-level prototyping.

 Assembly: Used for low-level hardware-specific programming.

3. Development Tools:

o Integrated Development Environment (IDE): Software like Arduino IDE,

MPLAB, or STM32CubeIDE is used to write, compile, and upload code.

o Programmers/Debuggers: Tools like USB ASP or JTAG interfaces allow code

to be uploaded to the microcontroller.

4. Programming Basics:

o Digital I/O: Controlling output pins (e.g., turning LEDs on/off) and reading input
pins (e.g., button presses).

o Analog I/O: Reading sensor data or controlling analog devices using ADC
(Analog-to-Digital Converter) and PWM (Pulse Width Modulation).

o Communication Protocols:

 I2C and SPI: For interfacing sensors and modules.

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  UART: For serial communication.

5. Steps in PCB Programming:

1. Write the code in the IDE using appropriate libraries for the microcontroller.

2. Compile and debug the code to check for errors.

3. Upload the code to the microcontroller using a programmer or USB interface.

4. Test the PCB functionality to ensure the program works as intended.

6. Basic Applications:

o Blinking an LED.

o Reading temperature from a sensor.

o Driving a motor or servo.

o Sending data wirelessly using modules like Bluetooth or Wi-Fi.

Why PCB Programming Matters:

PCB programming is the essence of embedded systems, enabling static hardware to perform
dynamic tasks. By combining hardware with software, it powers countless devices, from
household appliances to industrial automation systems.

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 CHAPTER 4 PCB COMPONENTS MOUNTING
Introduction to PCB Component Mounting

PCB component mounting refers to the process of attaching electronic components to a printed
circuit board (PCB) to create a functional circuit. Proper mounting ensures reliable electrical
connections, mechanical stability, and optimal performance of the PCB.

Types of Mounting Techniques:

1. Through-Hole Mounting (THM):

o Components with long leads are inserted into pre-drilled holes on the PCB and
soldered on the opposite side.

o Advantages:

 Strong mechanical bonds; ideal for components subjected to stress or

vibration.

o Disadvantages:

 Requires drilling; less suited for compact or high-density designs.

o Applications: Power supplies, large capacitors, connectors.

2. Surface-Mount Technology (SMT):

o Components are placed directly onto the surface of the PCB and soldered using
reflow soldering.

o Advantages:

 Compact, lightweight, and supports high-density designs.

 Suitable for automation, reducing production time.

o Disadvantages:

 Weaker mechanical bonds compared to through-hole components.

o Applications: Consumer electronics, communication devices, medical equipment.

3. Mixed Mounting:

o Combines both THM and SMT techniques on the same board.

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 o Used when certain components require through-hole mounting (e.g., connectors)
while others use surface-mount (e.g., ICs).

Key Processes in Component Mounting:

1. Placement:

o Components are aligned and positioned according to the PCB layout design.
Automated pick-and-place machines are often used for SMT.

2. Soldering:

o Wave Soldering: For THM components; the PCB is passed over a wave of
molten solder.

o Reflow Soldering: For SMT components; a paste of solder and flux is applied,
and the PCB is heated in an oven.

3. Inspection and Testing:

o Visual inspections, automated optical inspection (AOI), or X-ray imaging ensure

proper placement and soldering.

o Functional tests verify circuit operation.

Importance of Component Mounting:

 Ensures electrical connectivity between components and the PCB.

 Contributes to the durability and reliability of electronic devices.

 Affects manufacturability and cost of production.

By selecting the appropriate mounting technique, manufacturers can balance cost, performance,
and design complexity for various applications.

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 CHAPTER 5 PCB TESTING
Introduction to PCB Testing

PCB testing is the process of evaluating a printed circuit board (PCB) to ensure its functionality,
performance, and reliability. The goal is to identify manufacturing defects, verify that the design
works as intended, and ensure that the PCB meets quality standards before being used in
electronic products.

Types of PCB Testing:

1. Visual Inspection:

o The simplest form of testing involves visually examining the PCB for any obvious
defects, such as poor soldering, misplaced components, or visible damage.

o Automated Optical Inspection (AOI): Machines use cameras to inspect the PCB
for defects, ensuring components are placed correctly and soldering is uniform.

2. Electrical Testing:

o Continuity Testing: Verifies that all electrical paths are connected properly. It
checks for open circuits, shorts, or unintentional connections.

o In-Circuit Testing (ICT): Involves testing individual components on the PCB

using probes to measure voltages, resistances, and currents. It checks for
component placement, soldering, and the functionality of each part.

o Flying Probe Testing: A less intrusive form of ICT where probes move across
the board to check for electrical faults without requiring a dedicated fixture.

3. Functional Testing:

o Tests the PCB's functionality as a whole by simulating its operating conditions

and checking whether it performs the intended task (e.g., communication, signal
processing, or power regulation).

o Common in the final stages of PCB testing before the board is integrated into the
final product.

4. Burn-In Testing:

o The PCB is powered and subjected to stress tests (e.g., high voltage, high
temperature) for a prolonged period to detect early failures and ensure long-term
reliability.

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Introduction to PCB Testing

PCB testing is the process of evaluating a printed circuit board (PCB) to ensure its
functionality, performance, and reliability. The goal is to identify manufacturing defects,
verify that the design works as intended, and ensure that the PCB meets quality standards
before being used in electronic products.

Types of PCB Testing:

1. Visual Inspection:

o The simplest form of testing involves visually examining the PCB for any
obvious defects, such as poor soldering, misplaced components, or visible
damage.

o Automated Optical Inspection (AOI): Machines use cameras to inspect the

PCB for defects, ensuring components are placed correctly and soldering is
uniform.

2. Electrical Testing:

o Continuity Testing: Verifies that all electrical paths are connected properly.
It checks for open circuits, shorts, or unintentional connections.

o In-Circuit Testing (ICT): Involves testing individual components on the PCB

using probes to measure voltages, resistances, and currents. It checks for
component placement, soldering, and the functionality of each part.

o Flying Probe Testing: A less intrusive form of ICT where probes move across
the board to check for electrical faults without requiring a dedicated fixture.

3. Functional Testing:

o Tests the PCB's functionality as a whole by simulating its operating

conditions and checking whether it performs the intended task (e.g.,
communication, signal processing, or power regulation).

o Common in the final stages of PCB testing before the board is integrated into
the final product.

4. Burn-In Testing:

o The PCB is powered and subjected to stress tests (e.g., high voltage, high
temperature) for a prolonged period to detect early failures and ensure long-
term reliability.

5. X-ray Inspection:
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 o Used to inspect multi-layer PCBs, particularly for solder joints that are
difficult to inspect visually. It helps identify hidden defects such as voids or
cold solder joints.

6. Thermal Testing:

o Assesses the PCB’s performance under different temperature conditions,

ensuring components operate within their safe thermal limits and detecting
issues like thermal expansion or inadequate cooling.

Importance of PCB Testing:

 Ensures the PCB functions correctly before it is integrated into a larger system.

 Reduces the likelihood of product failures in the field, leading to higher quality and
reliability.

 Identifies manufacturing defects early, saving time and costs in rework or

replacements.

Effective PCB testing is crucial in modern electronics to maintain product quality, ensure
safety, and meet regulatory standards.

Importance of PCB Testing:

 Ensures the PCB functions correctly before it is integrated into a larger system.

 Reduces the likelihood of product failures in the field, leading to higher quality and
reliability.

 Identifies manufacturing defects early, saving time and costs in rework or replacements.

Effective PCB testing is crucial in modern electronics to maintain product quality, ensure safety,
and meet regulatory standards.

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 CHAPTER 6 CONCLUSION

In conclusion, understanding the fundamental aspects of PCB (Printed Circuit Board)

manufacturing, design, component mounting, programming, and testing is essential for ensuring
the functionality, reliability, and efficiency of modern electronic devices. The manufacturing
process, from material selection to component placement, plays a critical role in determining the
overall performance of the PCB. Proper PCB design and careful component mounting
techniques, whether through-hole or surface-mount, are key to optimizing both space and
electrical performance.

Programming of PCBs, particularly microcontrollers, allows for dynamic control over the
hardware, enabling diverse applications across industries. Moreover, rigorous testing
methodologies—such as visual inspection, electrical testing, functional testing, and burn-in—
ensure that the PCB meets the necessary standards for real-world use. By incorporating these
practices, manufacturers can guarantee the quality, durability, and functionality of their products,
ultimately contributing to the success and reliability of electronic systems.

This knowledge serves as a foundation for anyone involved in the design, development, and
production of electronic devices, highlighting the importance of each step in creating high-
quality, efficient PCBs.

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