Before You Start Routing
Good PCBs start with good schematics. Before you open your layout tool, make sure your schematic is complete, your component footprints are verified against actual datasheets, and your BOM has been cross-checked for availability. Fixing a footprint error after routing costs significantly more time than fixing it before.
Choose your EDA tool early and stick with it for the project. KiCad (free, powerful), Altium Designer (industry standard), and EasyEDA (browser-based, beginner-friendly) are the most common in Egypt's engineering community.
Choosing Your Layer Count
Most prototypes can be built on 2-layer boards. If your design is dense, has high-frequency signals, or requires a dedicated ground plane separate from signal routing, move to 4 layers. The cost jump from 2L to 4L is smaller than most people expect, and the signal integrity improvement is significant.
| Layer Count | Best For | Typical Cost |
|---|---|---|
| 1L | Simple power circuits, single-function boards | Lowest |
| 2L | Most prototypes, microcontroller boards, sensors | Low |
| 4L | RF designs, dense MCU boards, power management ICs | Medium |
| 6-8L | High-speed interfaces (USB 3.x, PCIe, LVDS) | Higher |
Design Rules That Matter
Before routing, configure your DRC (Design Rule Check) with the manufacturer's constraints. Common rules for standard PCB production:
- Minimum trace width: 0.1mm (6 mil) for standard production, 0.075mm (3 mil) for high-density
- Minimum trace spacing: 0.1mm clearance between traces and copper pours
- Minimum drill size: 0.2mm for vias, 0.3mm for through-hole components
- Annular ring: minimum 0.15mm around each drill hole
- Copper to board edge: minimum 0.3mm clearance on all layers
Important: Running DRC before exporting Gerbers is non-negotiable. A clean DRC report prevents the most common reasons for order rejection or rework.
Preparing Your Gerber Files
When you're ready to export, you'll need a complete Gerber package: copper layers (top and bottom), solder mask layers (top and bottom), silkscreen layers (top and optionally bottom), board outline (Edge.Cuts in KiCad, Mechanical 1 in Altium), and the drill file in Excellon format.
Always preview your Gerbers in a viewer (Gerbv is free and reliable) before submission. Confirm the board outline is closed, pads are properly masked, and silkscreen doesn't overlap pads.
- KiCad: File → Fabrication Outputs → Gerbers. Use the standard RS-274X format.
- Altium: File → Fabrication Outputs → Gerber Files + NC Drill Files.
- EasyEDA: Fabrication → PCB Fabrication File (Gerber).
DFM Tips That Save You Money
Design for Manufacturability is the practice of designing your board to minimize production cost and rework. Small changes at design time translate directly to lower prices and fewer defects.
- Keep via diameter at 0.3mm or larger to reduce drill-related costs
- Avoid NPTH (non-plated through holes) unless strictly necessary, as they add a separate drilling step
- Group similar components together to simplify assembly workflow
- Put fiducial marks on your board for SMT pick-and-place alignment
- Orient all polarized components (diodes, electrolytics) in the same direction to reduce assembly errors
From Prototype to Production
A good prototype order is 5–10 boards. This lets you verify the design, run basic tests, and identify any layout issues before committing to a larger run. Prototype pricing from Piclaro is based on board dimensions and layer count; you'll see exact pricing before you confirm.
When you're satisfied with the prototype, move to a small production run. The per-unit price drops significantly at 50+ boards, and our assembly partners can handle BOM procurement, pick-and-place, and reflow soldering, delivered to you tested and packaged.