We’ve seen hundreds of ways to create your own PCBs at home. If you have a laser printer, you can put traces on a piece of copper clad board. If you have some hydrogen peroxide and acid, you can etch those traces. Don’t have either? Build a tiny mill and cut through the copper with a Dremel. Making your own PCBs at home is easy, provided your boards are made out of FR4 and copper sheets.
Printed circuit boards can be so much cooler than a piece of FR4, though. Ceramic PCBs are the height of board fabrication technology, producing a very hard board with near perfect electrical properties, high thermal conductivity, and a dielectric strength similar to mineral transformer oil. Ceramic PCBs are for electronics going to space or inside nuclear reactors.
For his entry into this year’s Hackaday Prize, Chuck is building these space grade PCBs. Not only is he tackling the hardest challenge PCB fabrication has to offer, he’s building a machine to automate the process.
The basic process of building ceramic PCBs is to create a sheet of alumina, glass powder, and binder. This sheet is first drilled out, then silver ink is printed on top. Layers of these sheets are stacked on top of each other, and the whole stack is rammed together in a press and fired in a furnace.
Instead of making his own unfired ceramic sheets, he’s just buying it off the shelf. It costs about a dollar per square inch. This material is held down on a laser cutter/inkjet combo machine with a vacuum table. It’s just a beginning, but Chuck has everything he needs to start his experiments in creating truly space grade PCBs.