Latest Update: SpamButcher 2.1  
|
 Cutting Edge Spam Elimination This technical tip comes from the creator of the SpamButcher. If you need a program to minimize spam email, be sure to give the risk-free 21-day trial version a try.
Almost Frustration-Free Homebrew PCB via Laser Printer
At various points I've had the urge to make my own PCB boards. I found the process painful enough where I kind of abandoned this method of prototyping. Wirewrap is now the official electronics prototype method of SpamButcher combat robotics. That said - I've recently fumbled into a approach of transferring the toner "mask" to the boards which seems to yield better results that I've gotten from other methods. This article is just about getting the toner on the board - board design, etching / etc is all pretty well documented elsewhere.
The Paper - Mailing Label BackingMost people seem to be using inkjet photo paper for the toner transfer. This works - but I've had a lot better results using the backing of mailing labels.Specifically I've been using Avery Ink Jet Mailing Labels - 18163. Although it looks like they may have changed that product so it no longer contains a contiguous 8.5x11 backing sheet. That's right - go buy the address labels - take off the labels - and use your laser printer to print right onto the waxy sheet they came on. In fact - the toner transfers off so well - you can reuse the sheet!
Clean everythingClean the surface of your clothes iron and PCB board with a little rubbing alcohol. Scrub down the PCB board using synthetic iron-wool.
Preheat the boardThis is important. Apply the iron directly to the board - get it hot! This helps the toner transfer.
Place the printout on the boardApply the paper on the board before it cools down.It's important to get it right the first time. Since the board is hot - some of the toner will start sticking immediately. Avoid repositioning the sheet.
Apply pressure to the entire board with the ironIron the board up and down applying pressure. For best results - try pushing down with the tip or side of the iron.
Slowly start to peel back the paperWhen you start to peel back the paper - you'll inevitably hit some areas that didn't transfer fully.Not a problem - lay the paper back down, and then apply more pressure with the iron. Slowly pull the paper up again. Does it look good now? Then pull back the paper a little farther. Continue the process until you've pulled the entire sheet up. You should have a near-perfect transfer, and there should be very little toner left on the sheet at all. There you go - no soaking / peeling paper off the board. Further - you can probably use the transfer sheet again. If you totally botched it - use the iron to transfer any remaining toner from the sheet to the board. Then, scrub down the board with some rubbing alcohol and the synthetic steal wool. You can then re-use both the paper and the board to give it another go without having to throw anything out.
| 
Over 300,000 Downloads! 
"consistently kills 97% of the over 250 spam I get each day" -Rich |