Project: CNC PCB Maker

This project transformed my Genmitsu 3020 Pro CNC machine into a specialized PCB manufacturing system, enabling me to produce professional-quality printed circuit boards at home. The setup allows for complete control over the PCB fabrication process, from initial design to finished product.

The workflow integrates industry-standard software tools: KiCad for PCB design and Gerber file generation, FlatCAM for converting Gerber files into CNC toolpaths, and Candle for real-time G-code execution and machine control. This combination provides a cost-effective alternative to commercial PCB fabrication services for prototyping and small-batch production.

The system can handle single and double-sided PCBs with trace widths as small as 0.1mm, making it suitable for most hobbyist and prototype applications. The ability to produce PCBs on-demand significantly reduces development time and allows for rapid iteration of designs.

CNC Machine Specifications

• Genmitsu 3020 Pro CNC Router
• Working area: 300mm x 200mm x 45mm
• Spindle speed: 10,000-24,000 RPM
• Step resolution: 0.01mm accuracy
• 3-axis stepper motor control

Cutting Tools & Accessories

• 0.1mm V-bit engraving bits for trace isolation
• 0.8mm carbide end mills for drilling vias
• 1.0mm drill bits for component holes
• Custom PCB holding fixtures and clamps
• Vacuum table for secure workpiece holding

PCB Materials

• Single-sided copper-clad FR4 boards
• Double-sided copper-clad boards for complex designs
• Standard thicknesses: 1.6mm and 0.8mm
• High-quality copper surface finish

Complete PCB Manufacturing Workflow

KiCad PCB Design Process

• Schematic capture and component placement
• PCB layout with design rule checking (DRC)
• Copper pour and trace routing optimization
• Gerber file generation for manufacturing layers
• Drill file export for via and component holes

FlatCAM Toolpath Generation

• Import Gerber files and align layers
• Configure tool parameters (speed, feed, depth)
• Generate isolation routing for traces
• Create drilling operations for holes
• Optimize toolpaths for efficient machining
• Export G-code for CNC execution

Candle CNC Control

• Machine setup and coordinate system alignment
• G-code loading and visualization
• Real-time machining control and monitoring
• Emergency stop and pause functionality
• Progress tracking and completion notifications

CNC Machine Modifications

• Installed precision spindle mount for consistent tool positioning
• Added vacuum hold-down system for secure PCB clamping
• Implemented dust collection to maintain clean work environment
• Calibrated axis movement for 0.01mm positioning accuracy
• Set up emergency stop systems for safe operation

Software Configuration

• Configured FlatCAM tool database with cutting parameters
• Set up Candle for proper communication with CNC controller
• Established coordinate systems and work offsets
• Created custom post-processors for G-code optimization
• Implemented safety protocols and limit checking

Challenges Overcome

• Achieving consistent depth control for trace isolation
• Managing copper burr formation during cutting
• Optimizing feed rates for different copper thicknesses
• Developing reliable workpiece clamping methods
• Minimizing tool wear through proper speed/feed combinations

Quality Testing Procedures

• Electrical continuity testing of all traces and connections
• Isolation resistance measurement between adjacent traces
• Dimensional accuracy verification using digital calipers
• Visual inspection for copper burrs and surface defects
• Hole size and position accuracy checking

Process Optimization

• Fine-tuned cutting speeds for optimal surface finish
• Optimized tool depths to prevent over-cutting
• Developed standard operating procedures for repeatability
• Created quality checklists for consistent results
• Implemented tool wear monitoring and replacement schedules

Performance Validation

• Successfully manufactured test PCBs with 0.1mm trace spacing
• Achieved 95%+ yield rate on prototype boards
• Verified compatibility with standard SMD components
• Tested through-hole plating alternatives
• Validated multi-layer registration accuracy

Sample PCB Gallery

The system has successfully produced various PCB designs including microcontroller development boards, sensor breakout boards, and small-scale production runs for personal projects. Each board demonstrates the precision and quality achievable with this desktop manufacturing setup.

Future Improvements

• Implementation of automatic tool changing for multi-operation boards
• Development of through-hole plating processes
• Integration of pick-and-place capabilities for automated assembly
• Expansion to 4-layer board manufacturing
• Addition of solder mask application techniques

Learning Outcomes

This project provided comprehensive experience with the complete PCB manufacturing workflow, from design concept to finished product. The integration of multiple software tools and hardware systems developed valuable skills in manufacturing engineering, process optimization, and quality control. The ability to rapidly iterate designs and test manufacturing parameters has been invaluable for subsequent electronics projects.