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Outline
This procedure is used to repair mechanical or thermal damage to the circuit board base material. This method is used when extended areas of base material must be completely replaced. This method may be used on single-sided, double-sided, or multilayer circuit boards or assemblies.
Caution: Surface circuits may need to be replaced in the damaged area. Be sure that the appropriate circuit diagrams or photographs reflecting the original circuits are available so that they may be replaced after repairing the base board material. Damage to internal circuits or planes may have to be restored using surface wires.
Minimum Skill Level - Expert
Recommended for technicians with advanced soldering and component rework skills and extensive experience in most repair/rework procedures.
Conformance Level - High
This procedure most closely duplicates the physical characteristics of the original, and most probably complies with all the functional, environmental and serviceability factors.
| Acceptability References |
| IPC-A-600 2.0 |
Externally Observable Characteristics |
| IPC-A-610 10.0 |
Laminate Conditions |
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| Part No. / Item / Description |
Price |
Order |
Base Board Repair Kit
Kit to repair base board and laminate damage on circuit boards.
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$245.00 Each |
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Circuit Bond Kit
Includes clear, low viscosity, superior strength epoxy for circuit board damage repair.
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$195.00 Each |
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Flex-Rack PCB Holder
Sturdy rack for PCBs used for rework and positioning.
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$595.00 Each |
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Master Repair Kit
Kit to repair circuit board damage including pads, lands, conductors and base material.
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$729.00 Each |
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Micro Drill System
Versatile power tool for milling, drilling, grinding, cutting and sanding.
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$589.00 Each |
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Precision Tool Set
Nine precision-crafted tools for detailed circuit board work.
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$106.00 Each |
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Professional Repair Kit
Kit to repair damaged pads, lands, conductors, base material, and plated holes.
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$1029.00 Each |
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Cleaner
General purpose cleaner for removing contamination.
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End Mills
Designed for end cutting and hole boring.
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Microscope
Precision microscope with stand and lighting for work and inspection.
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Oven
General purpose oven for drying, baking and curing epoxies.
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Precision Drill
Precision drill press for accuracy and controlled depth drilling.
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Learn More |
Learn More |
Wipes
Nonabrasive, low-linting wipes for cleanup.
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Procedure
- Clean the area.
- Mill away the damaged board material using the Micro-Drill System and ball mill. Remove all evidence of the damaged material. No fibers of laminate material should be exposed. At the surface, file the edges to ensure the opening is rectangular or uniform. (See Figure 1)
Caution: Abrasion operations can generate electrostatic charges.
- Clean the area.
- Bevel the edge using the Micro-Drill System and ball mill or a file. (See Figure 2) Install an end mill into the chuck of a Precision Drill System. Set the speed to maximum and machine a step or lap joint on the edge of the circuit board where the new base material will be installed. The depth and width of the step should be approximately 1/2 of the circuit board thickness. (See Figure 3)
Caution: Exercise care to avoid damage to any internal conductors. If any internal conductors are damaged, surface wires may be required.
- Cut or machine a piece of replacement base board material of the same thickness and type as the piece removed. The replacement piece must also be the same size and shape as the opening, including the step joint.
- Install an end mill into the chuck of a Precision Drill Press. Machine a step onto the entire mating edge of the replacement base material. The step's dimensions should match the step's size in the circuit board milled groove. (See Figure 4)
- Where required, apply High-Temperature Tape to protect exposed parts of the circuit board bordering the prepared area.
- Check the fit to be sure the new base material properly mates with the step in the circuit board.
- Mix the epoxy.
- Coat both the tongue and groove surfaces with epoxy and fit together. (See Figure 5) Remove excess epoxy.
- Cure the epoxy per Procedure 2.7 Epoxy Mixing and Handling.
- After the epoxy has cured, remove the High-Temperature Tape.
- If needed, scrape off any excess epoxy using a knife or scraper.
Note: If needed, apply a thin coating to seal any scraped areas.
- Clean the area.
- Complete by drilling holes, slots, etc., or adding circuitry as required.
Evaluation
- Dimensions of the area replaced should be checked to conform to the specifications required.
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