Smart Timer Controlled PCB Etching System for Next Generation

Precision Manufacturing

P Subramanyam Raju, S Munavvar Hussain, P Sai Dileep Varma, P Aditya Varma and M Sai Ram

ECE Department, B V Raju Institute of Technology, Narsapur, Medak(dist). Telangana, India

Keywords: Etching Time Calculation, Micro Controller, LCD Display, Printed Circuit Boards-PCB.

Abstract: The technology of today is mechanized. from au tomated parked to vehicle alarm systems. Due to the rapid

development of technology, people are compelled to invent tools that will make life easier for them. The

etching process, which creates a path or plan that will connect electrical components, is also called the printed

circuit board screen printing process. A PCB etching machine, with a mix of chemical solutions such as ferric

chloride, dissolves metal components not intended to be used on standard PCB boards. Manual PCB methods

are often time-consuming and expose users to ferrit chloride solutions. Designing a printed circuit board

(PCB) etching machine with a timer is a cutting-edge method of automating the PCB production process to

boost its accuracy. The objective of this project is to include an electronic timer to precisely control the etching

time and provide dependable results that ensure ’best quality’. The automatic timing system does away with

hand interventions, minimizes human error, and ensures safety and fewer interactive exposures to the etching

chemicals. This machine employs the use of a timer, a reliable and efficient solution toward small scale

manufacturers to simplify the process of creating PCB with accurate and consistent outcomes.

1 INTRODUCTION

The rapid change in technology has swept into the

automation of various operations, now encompassing

even printed circuit board (PCB) etching. PCBs form

the basic electronic component, basically used in all

modern electronic devices. In PCB etching,

conductive paths for electrical components on a board

are created through dissolving unwanted metal using

chemical solutions, such as ferric chloride.

Traditional methods of etching PCBs are normally

characterized as quite labour-consuming and expose

the operator to hazardous chemicals, a matter of

safety risk (Clark, 2012). To improve accuracy and

consistency in the etching process, timer-controlled

systems have been introduced. These systems allow

for precise control of etching time, ensuring

uniformity and reducing human error. Early work in

this area highlighted the benefits of using timers to

control etching durations, improving the quality and

consistency of etched circuits (Doe, Smith, et al. ,

2019). As the demand for more reliable

manufacturing processes increased, automation with

timers based on micro-controllers became

widespread, which ensured improved reliability and

productivity in industrial processes(Gupta and

Sharma, 2020). improve the etching process’s

accuracy (Patel and Kumar, 2021). Moreover, studies

indicate that minimizing variations in etching time

leads to more uniform results, and hence, the process

results are further improved in reliability (Chen and

Nguyen, 2023).Some closed-loop feedback control

mechanisms have also contributed much to the

designs as they include the elements like sensors and

timers, which help adjust the etching process

dynamically with respect to time in real time

operation for optimal results throughout the operation

(Thompson and Brown, 2018), (Martin and Zhao,

2019). Such systems are found to improve overall and

also increase PCB etching performance with

efficiency (Martin and Zhao, 2019). Besides the

improvement of control over the process, the

development of timers designed especially for

automation ensured greater reliability and more

consistency of the PCB etching process, particularly

in small manufacturers who require efficient high

quality production methods (Wilson and Martinez,

2021).

Subramanyam Raju, P., Munavvar Hussain, S., Sai Dileep Varma, P., Aditya Varma, P. and Sai Ram, M.

Smart Timer Controlled PCB Etching System for next Generation Precision Manufacturing.

DOI: 10.5220/0013600600004664

Paper published under CC license (CC BY-NC-ND 4.0)

In Proceedings of the 3rd International Conference on Futuristic Technology (INCOFT 2025) - Volume 2, pages 715-721

ISBN: 978-989-758-763-4

715

2 RELATED WORK

The recent developments in timer-controlled PCB

etching systems have improved significantly the

precision and efficiency of fabrication. This can be

attributed to the fact that modern electronics

manufacturing has progressively applied timer-based

control methods because they can amplify accuracy

and the consistency of the outcome results of etching.

Recent comprehensive reviews of timer control

techniques pointed out the increased use and

significance of these systems towards improving PCB

etching quality, with accurate timing mechanisms

resulting in considerable improvements in the overall

etching process (Singh and Verma, 2022). Advancing

the core concept, intelligent timer systems, especially

those involving artificial intelligence, seem

promising for improved accuracy and stability in the

process. Such systems have demonstrated measurable

improvements in the precision of etching and the

reliability of the manufacturing process, addressing

some of the key challenges faced in traditional

manual methods (Jones, Wang, et al. , 2023). The

benefits of timer-controlled PCB etching extend

beyond accuracy and stability; automation also

improves the overall efficiency of the process by

minimizing human error. Automated timing systems

were proved to accelerate the throughput

considerably by smoothing etching time with

minimal variation in it, thereby establishing

consistency in the final product. Further, timer control

through the use of advanced algorithms improved reli

ability and efficiency of the etching process and made

possible more complex optimization strategies of

etching control (Nguyen, Lee, et al. , 2021), (Roberts,

Lee, et al. , 2020). More importantly, calibration

studies of timer systems in mass PCB production

have highlighted the significance of proper

calibration techniques. In mass production, accurate

calibration of the time controls ensures homogeneous

quality, an area where the optimization of the etching

process for its industrial application has been a major

area of focus (Wang, Zhao, et al. , 2021). More

efficient and precise PCB etching became possible

because of modern manufacturing techniques

coupled with the advancements in timer-controlled

systems (Brown and Miller, 2020)

3 EXISTING MODEL

The smart timer-controlled systems for PCB etching

have greatly improved the level of precision and

efficiency in the manufacturing process. These

systems rely on intelligent algorithms with real-time

feedback to optimize etching time, minimize

variability in the process, and improve product

quality. The basics begin with the automation of

timers, which essentially makes the process

smoother, more consistent, and more accurate in

results (Clark, 2012). The earliest experiments

involved the automation of etching. This aspect was

approached with a micro controller-based timer to

automate etching. The etching was controlled

accurately so as to eliminate human error, which

finally brought more accuracy to the output. Over

time, integrating real-time feedback and smart control

algorithms further improved the accuracy of these

systems, creating adaptation for different conditions

in the manufacturing environment. These

developments set the stage for more advanced timer-

controlled systems that include intelligent features of

dynamic adjustments, ensuring optimal performance

throughout the etching process (Doe, Smith, et al. ,

2019). Recently, AI-based smart timers are added to

improve the control and accuracy of the system. The

intelligent systems continue to monitor and adjust

parameters based on required precision levels

achieved in real time. With intelligent smart timers

added recently, the modern PCB manufacturing

demands a more reliable and efficient solution. The

use of advanced algorithms in the etching process

ensures not only its precision but also its adaptability,

the ability to compensate for variations or quirks

within the manufacturing environment. Calibration of

these smart timer systems is important to give them

the very high accuracy next-generation PCB etching

demands for overall improvement in the

manufacturing process (Lee, Wang, et al. , 2022).

Overall, these smart, timer-based systems greatly

enhance the PCB etching, reducing variance and

improving product quality and effectiveness.

Continued development and improvement of these

technologies will usher in a future of highly

automated, accurate, and reliable PCB manufacturing

processes.

4 PROPOSED MODEL

The timer-controlled PCB etching machine proposed

is designed to have outputs of high performance with

flexibility and user-friendliness. The timing

mechanisms within the system are highly precise to

uniformly etch surfaces of PCBs, thus averting

defects and significantly improving PCB product

quality. Precise timing is utilized to control the

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duration in which the etching process executes the

etching operation with a high degree of accuracy,

signifying that the same quality would be acquired in

different batches. The programmable setting of the

machine will be aligned with various PCB designs,

materials, and production requirements. Users will

easily configure critical process parameters such as

etching time and solution temperature through an

intuitive user interface to allow for flexibility in

tailoring the system to specific applications. It also

combines with the use of IoT technology that

remotely monitors and controls the system real-time.

Through IoT connectivity, the etching parameters can

be adjusted and the performance of the system

monitored. Also, it is equipped with the ability to send

notifications and alerts from anywhere so that one is

ensured not to miss anything that would disrupt the

process. One of the most significant advancements of

this system is its ability to offer automated

calibration. The system thus ensures that it is in its

best operating state and forms a precise setting

throughout the progress. It will constantly monitor

critical parameters and adjust itself to maintain

precision by eliminating manual recalibration

processes. Built-in maintenance alerts reduce

downtime because they remind the users when

maintenance or system checks are in order, thereby

improving the reliability and availability of the

system. This automation is especially helpful in

limiting human errors and ensuring that the output

quality will be uniform in large-scale manufacturing

environments. It can further carry multi-stage etching

processes, which assist the system in processing com

plex PCB designs that involve numerous layers or

complicated patterns. In this manner, the device

offers more flexibility for the fabrication process to

manufacturers of advanced and high-density circuits,

making them compatible with future electronic

devices.

This design of the machine is cost-effective,

which makes it possible for advanced features such as

programmable etching parameters, IoT integration,

and automated maintenance to be made accessible for

small and medium-sized manufacturers, educational

institutions as well, without compromising quality or

performance on the aspects of performance. This

equipment is also constructed with security features,

including automatic shut down in cases of

malfunction or specific operational ab normalities,

which also protects the machine and the operator.

Procedures for safety measures to ensure a risk-free

working environment have been included. When the

accident occurs, the machine will automatically shut

off. This prevents damage to the machine and ensures

the process is not interrupted. The rather compact

machine design also permits easy integration into an

existing production line. Being modular, it is

designed to allow easy upgrading and maintenance

and will enable manufacturers to enhance the system

as the production requirement changes with time. In

this regard, the machine could be that robust,

efficient, and reliable solution that would match

large-scale industrial PCB manufacturing

requirements with relatively smaller, specialized

production environments. The flowchart outlines the

operation of a PCB etching machine equipped with a

timer for precise automation. Here’s a breakdown of

each step: Start: The process begins with initiating the

system. Setup: Initial configurations are made. This

step ensures that all parameters required for etching

are properly set.

Figure 1: flowchart

Figure 2: Block diagram

Set Timer: A timer is set to control the etching

duration accurately. This step ensures precision. No:

If the timer is not set, the process loops back to

”Setup.” Yes: If the timer is successfully set, it

proceeds to the etching process. Start Etching: The

etching process begins. Countdown Timer: The

system counts down the time, ensuring the process

adheres to the preset duration. Monitor Process: The

etching process is continuously monitored for safety

and consistency. End Etching: Once the timer ends,

the etching process stops automatically. Complete

Etching: After the etching process finishes, the results

are reviewed or finalized. Shut Down: The machine

safely shuts down after the process completes. The

Smart Timer Controlled PCB Etching System for next Generation Precision Manufacturing

717

block diagram represents an automated PCB etching

machine equipped with a timer to enhance precision

and safety in the PCB production process. Here’s an

explanation of the blocks in the diagram, as they align

with the abstract and image: AC Supply: This

provides the initial electrical power re quired for the

entire system. Transformer: Converts the AC supply

into a lower voltage level suitable for the components

in the circuit. Rectifier: Converts the AC voltage into

DC voltage to power electronic components such as

the micro-controller. Regulator: Ensures the DC

voltage remains stable and within the range required

by the system components, protecting them from

fluctuations. Micro-controller: Serves as the core

processing unit of the system. It controls the operation

of the etching machine, including timing and safety

functions. It interfaces with other components like the

LCD display, buzzer, relay, and DC motor to

automate the etching process.

LCD Display: Provides a user interface to display

real-time information, such as the etching time and

operational status. Buzzer: Alerts the user when the

etching process is complete or in case of any errors,

improving safety and usability. Relay: Acts as a

switch controlled by the micro controller to regulate

the power supply to the DC motor, which is

responsible for operating the etching mechanism. DC

Motor: Drives the mechanical components of the etch

ing machine, such as agitation or movement of the

PCB during the etching process, ensuring uniform

results The diagram shows a micro controller-based

system that controls various components. AC power

is stepped down by a transformer, converted to DC by

a rectifier, and regulated for stability. The micro

controller runs the system, displaying info on the

LCD, controlling a DC motor via relays, and

triggering a buzzer for alerts. The entire process is

programmed.

5 METHODOLOGY

The methodology for developing a ”smart timer-

controlled PCB etching system for next-generation

precision manufacturing” is designed to incorporate

high-precision timing control and programmable

settings and integrate with the internet of things in the

goal of optimizing the etching process. A micro

controller-based system, such as Arduino or STM32,

would be used at the base level to ensure precise

timing and control over the etching process. These

micro controllers will perform the core functions,

including controlling etching time along with

temperatures and agitation of the solution to achieve

uniform etch. According to previous works, this

mechanism was enabled in the system under

construction. This will make possible flexible

essential parameters, namely, etching time,

temperature, and stage setting, for several designs and

various materials used in PCBs. This is along the

principles of automation with flexibility and

personalization in the manufacturing system of PCB

that takes center stage. The fact that the system is

programmable means that it incorporates features and

suitability for varying etching needs which do not

require manual readjustment, ensuring efficiency and

precision. It will be Io T-capable for real-time

monitoring and control of the system based on the

model constructed by continuous data accumulation

from parameters such as temperature and etching

progress, so that adjustments may be done remotely

through a dedicated interface in terms of the real-time

feed back and control strategy. In addition, automated

calibration techniques will be incorporated into it,

ensuring uniform performance and avoiding down

times, with maintenance reminders to the users.

Another benefit is that it will include multi-step

etching features to manage intricate PCB designs.

These characteristics will enable the etching of

intricate designs for the highest caliber of results.

Finally, as previous research has shown the

importance of safety and simplicity of integration into

a manufacturing system, safety features and

adaptability will be established.

Ferric Chloride (FeCl3) for PCB Etching Ferric

chlo ride(FeCl3) is one of the most commonly used

et-chants for printed circuit board (PCB) etching due

to its affordability, efficiency, and widespread

availability. The chemical reaction involved in the

etching process is: The chemical reaction is: CuCl2

+Cu− >2CuCl (1) In this reaction, copper reacts with

ferric chloride, producing copper chloride (CuCl2)

and ferrous chloride (FeCl2). The ferric chloride

oxidizes the copper, effectively removing un wanted

areas and exposing the desired circuit pattern. This

reaction is efficient and provides reliable results, mak

ing ferric chloride a popular choice in both hobbyist

and professional PCB fabrication. In preparation for

the etching solution, dissolve 1 part ferric chloride in

2 parts water. Add the ferric chloride to the water

slowly, and not the other way around, so that the

solution is not splashed and a burn is not experienced.

Heating the solution to 40-50°C increases the

reaction, reducing the etching time to 10-20 minutes.

The process is agitated gently so that copper is

removed uniformly and does not etch unevenly.

Despite its efficacy, ferric chloride has some

disadvantages. It permanently stains surfaces and

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skin, and thus, protective gear like gloves and aprons

must be used. Also, proper disposal is required since

the solution can contaminate water sources if

mishandled. Therefore, ferric chloride should be

handled with care to ensure safe and successful PCB

etching. Ammonium per sulfate is very efficient et-

chant for copper. It gives precise etching results with

cleanliness of the etched surface. Its chemical

reaction with copper involves the oxidation of the

latter to form copper sulfate and ammonium hydrogen

sulfate, respectively: (NH4)2S2O8 +Cu− > CuSO4

+NH4HSO4 (2) To prepare the etching solution,

dissolve 250 grams of ammonium persulfate in 1 liter

of warm water at approximately 50°C. Maintaining

this temperature enhances the dissolution rate and

overall etching efficiency. The etching process typi

cally completes within 5-10 minutes, but continuous

stirring is recommended to accelerate the reaction and

ensure uniform etching. One of the significant

advantages of ammonium persulfate is that it forms a

clear solution, and thus, etching can be visually

monitored. However, ammonium persulfate is less

stable than most etchants. It decomposes with time,

especially at high temperatures, and thus, the solution

has to be prepared fresh before use for maximum

performance. Moreover, temperature control is very

important; deviations affect the etching speed and

quality. ammonium per sulfate is suitable for high-

precision applications if the solution is fresh and the

temperature is properly controlled.

Copper Etching:

CuCl2 +Cu → 2CuCl

Regeneration:

2CuCl + 2HCl + H2O2 → 2CuCl2 +H2O (3)

Cupric chloride (CuCl2) is a versatile and

reusable et-chant widely used for copper etching. Its

reaction with copper produces cuprous chloride

(CuCl2), which can be regenerated with hydrogen

peroxide (H2O2) and hydrochloric acid (HCl),

allowing the etchant to be reused multiple times. The

primary chemical reactions involved are: Preparation

of the etching solution To obtain an acidic

environment, the solution of cupric chloride

dissolved in hydrochloric acid has a hydrogen

peroxide added to it, which acts as a restorative agent

in the etching process. The etching is able to remove

the copper within 5 to 15 minutes, depending upon

the concentration of the etching solution, temperature

and the thickness of the copper. Etching with a little

agitation increases the contact of the solution with the

surface and results in uniform etching. One of the

significant advantages of cupric chloride is that it can

be reused, which makes it a cost-effective option in

the long run. The regeneration process ensures that

the solution remains effective, thus minimizing waste

and environmental impact. However, it requires

careful management. Over addition of hydrogen

peroxide results in over-etching, where the copper is

etched too aggressively, potentially damaging fine

details. Overuse of(H2O2) also destabilizes the

solution and produces unwanted byproducts.

Optimize the performance by checking its

concentration, acidity, and oxidation state. Cupric

chloride can be handled with due care, regenerated,

and is safe to use for both small scale and industrial

copper etching purposes. This method will enable the

system to contribute to reliable, cost-effective next-

generation PCB manufacture.

6 RESULTS

This is an etching machine for a PCB with a timer of

a design intended to automate and enhance the

accuracy of the etching process. It contains an LCD

display of timer status, control knobs, and buttons for

user input. The stepper motor drives a rotating disc to

ensure optimal exposure of chemical etching. The

transparent acrylic panel increases safety in operation

by decreasing contact with etching chemicals while

watching. Made of low-cost materials such as wood

and acrylic, this machine is highly suitable for small-

scale PCB manufacturers. The machine eliminates

Figure 4: Designed model

Smart Timer Controlled PCB Etching System for next Generation Precision Manufacturing

719

Figure 5: Simulation

manual errors, thus providing accurate and consistent

results. It makes for an efficient, reliable solution for

producing high-quality PCBs. The pictured PCB

etching machine contains an LCD display along with

a digitally controlled automated timer. The timer,

being managed by micro-controller, does not need

manual intervention, thereby giving a highly accurate

result coupled with safety aspects. Automating

etching time minimizes the operators’ exposure to

hazardous chemicals like ferric chloride besides

eliminating human errors and thus achieving

increased operator safety. The LCD display shows

real-time etching time updates, thus making the

process much easier for smaller manufacturers of

PCBs. This efficient, reliable solution simplifies PCB

production while ensuring dependable and high

quality results, improving safety and productivity in

small scale electronic manufacturing.

7 CONCLUSIONS

The PCBetching machine with an electronic timer

offers the world a modern solution in the face of

challenges associated with the traditional manual

PCB production. Given that this machine automates

the etching process, its main advantages include

increased precision, less human error on the part of

the user, and safety in terms of exposure to dangerous

chemicals, such as ferric chloride.

This innovative approach guarantees consistent

and high-quality outputting results, making it very.

important for small-scale manufacturers. The use of a

timer streamlines the process of PCB making, by

ensuring a more reliable, efficient, and safer means of

production as compared to traditional methods. This

project demonstrates the potential of automation in

helping improve productivity and quality of PCBs

produced.

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