What is PCB clone?

PCB clone is a duplicated printed circuit board, a copy of an existing PCB

PCB cloning refers to the reverse engineering of a circuit board based on the existing physical electronic product and circuit board, utilizing reverse research and development techniques. The primary objective is to accurately reproduce the technical documents of the original product, including PCB files, Bill of Materials (BOM) files, schematic files, and so forth. Subsequently, with these restored technical materials and production guidance documents, the manufacturing of PCB boards, precise soldering of components, rigorous flying probe testing, and necessary functional debugging of the circuit board are carried out. This comprehensive process results in the duplication of the original circuit board prototype, achieving a complete reproduction of its functionality.

II. The Process of PCB Copying

The process of PCB Copying is intricate and meticulous, encompassing several key steps:

Component Disassembly and Documentation

Disassembling Components: Initially, all components on the PCB are meticulously disassembled. During this phase, careful records are kept of each component's model, specifications, and position, particularly the orientation of diodes, transistors, and IC chips. Ideally, photographs are taken to document the component layout, ensuring no detail is overlooked. This information is vital for subsequent restoration work.

Compiling the BOM: Based on the disassembled components, a Bill of Materials (BOM) is compiled to facilitate subsequent procurement and soldering tasks.

Empty Board Scanning and Image Processing

Cleaning and Scanning: The empty PCB is thoroughly cleaned with alcohol or other cleaning agents before being scanned using a high-precision scanner. Proper alignment is crucial to obtain a clear image.

Image Processing: Image processing software is employed to adjust contrast, brightness, and other parameters to enhance the visibility of solder pad markings. The image is then converted to black and white, and line clarity is verified. If necessary, adjustments are repeated or rescanning is performed.

Storing and Converting Formats: The processed images are saved in black and white BMP format, typically comprising top (TOP.BMP) and bottom (BOT.BMP) layers, with any necessary repairs or corrections applied.

PCB File Conversion and Layout

File Conversion: PCB design software is used to convert BMP files into a format recognizable by PCB manufacturing equipment, ensuring accurate PAD and VIA (through-hole) placements.

Drawing the PCB Layout: With the converted files, the PCB layout is redrawn in the PCB design software. This step requires immense patience and attention to detail to ensure the precise positioning of each layer's circuitry and components.

PCB Fabrication and Component Soldering

PCB Fabrication: The finalized PCB layout is sent to a fabrication facility for production.

Component Procurement and Soldering: Components are procured based on the BOM and then soldered onto the manufactured PCB, with utmost care taken to adhere to the original component orientations and positions.

Testing and Debugging

Flying Probe Testing: Utilizing a flying probe tester, the soldered PCB is subjected to rigorous tests to verify the accuracy of circuit connections and the quality of soldering.

Debugging and Optimization: The PCB is integrated into the relevant system for functional testing, and adjustments are made as needed to ensure performance parity with the original board.

As a pivotal reverse engineering technology, PCB Copying plays an irreplaceable role in driving electronic industry growth and fostering technological innovation. It transcends mere replication, delving into the depths of circuit design for learning and reinvention. At Tecoo Electronics Co., Ltd., we remain steadfast in our commitment to professionalism, innovation, and integrity, offering high-quality PCB Copying services and technical support to collaborate with clients in advancing the prosperous development of the electronics industry.