Operation Tight Spots

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Damage Free Pad Removal

A proven method of circuit removal in tight places.

Figure 1: Dashed lines indicates material removed from knife blade to modify it for precision pad removal.

The proliferation of high-frequency and microwave printed circuits, generally used in the communications, automotive and aerospace industries, is underway. Anyone familiar with these products understands the sensitive design considerations each requires. Occasionally, you may encounter the need to reduce a circuit pattern size when a pad or conductor is violating space requirements. This type of modification is an extremely delicate operation requiring not only the hands of a surgeon, but the use of customized tools modified specifically for the application.

Recently, we were presented with such a challenge. We were asked to remove a section of a pad to provide the specified separation of the pad from a conductor running close by.

The precision needed to cut this pad could have been done with a standard carbide cutter and milling machine, but controlling the depth of the milling would have been difficult on this project. Using a simple hand-held knife to cut and remove the section was the method we used. However, we first needed to modify the knife blade and then place the knife into milling machine. (See Figure 1).

Figure 2: Knife is placed in a milling machine. Milling machine is not turned on, it is used to precisely control the movement of the knife.

A special fixture to support the board, was developed. The modified blade was placed in the knife, and the knife was installed into the collet of the milling machine. The milling machine was never turned on, it was just used to precisely control the movement of the knife. You might expect to cut completely through the entire depth of the pad on the first pass - not so! If you did you may cut too deep, causing a "crazing" of the base board material, and thus, damage. Even the slightest penetration of the base material, beyond the depth of the pad may cause damage. Thus the knife was set to cut three-fourths of the way through the pad. The final pad material was removed by hand allowing for a more controlled removal, without damaging the adhesion of the remaining pad. Modifying standard knife blades is not difficult and can be accomplished using grinders and files.

This is a special modification calling for special tools and fixtures. A milling machine, or similar precision coordinate systems is also needed.

Several members of the Circuit Technology Center team contributed to this feature story.