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How to Cut PCBs? Essential Tools, Methods and Expert Guides

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PCB cutting can make or break your electronics project. Whether you’re crafting a one-of-a-kind prototype or preparing for mass production, getting it right is essential. But with so many tools and techniques available, where do you start? This comprehensive guide will walk you through everything you need to know about cutting PCBs, from the basics to advanced methods.

Why Cutting PCBs?

In generally, we need to cut the PCBs for:

  • Prototyping: Fit in custom enclosures, separate functional sections for testing.
  • Repair and Modification: Remove faulty component areas, create space for new components.
  • Manufacturing Optimization: Separate panelized PCBs, reduce material waste.

PCB Cutting Methods

Manual Cutting

Tools: Utility knife, heavy-duty scissors, hobby knife

  • How it works:
    • Score the PCB surface with a blade, then snap along the line (for thin boards like single-layer fiberglass).
    • Use scissors for quick, rough cuts in non-critical areas.
  • Best for:
    • Thin PCBs (≤1.6mm), small batches, or temporary prototypes.
  • Limitations:
    • High risk of uneven edges or board warping.
    • Not suitable for thick or multi-layer boards.
A person wearing transparent goggles and a light - blue mask is manually scoring and snapping a green circuit board on a light - colored wooden workbench.
Manual Cutting - Score and snap method on a PCB.

CNC Precision Cutting

Tools: CNC machine + carbide routing bits

  • How it works:
    • Program a design into the machine, which mills the PCB using rotating bits.
  • Best for:
    • High-precision cuts, intricate shapes, or multi-layer PCBs.
    • Small-scale production runs.
  • Pros:
    • Consistent, burr-free edges and repeatable results.
  • Cons:
    • High upfront cost (hundreds to thousands of dollars).
    • Requires CAD software and technical setup.
A precision CNC machine with black and red body is processing a green printed circuit board. The operation panel has multiple buttons and a display showing the "G" character, and some debris is generated during the processing.
CNC cutting of a PCB.

Laser Cutting

Tools: Fiber laser or CO2 laser (industrial-grade)

  • How it works:
    • A high-power laser vaporizes the PCB material along the cut path.
  • Best for:
    • Micro-scale components or complex geometries (e.g., flexible PCBs).
  • Key Considerations:
    • Avoid hobby lasers: They often lack safety features and may ignite PCB materials.
    • Produces minimal debris but requires fume extraction for toxic byproducts.
An industrial fiber laser marking machine is engraving "Laser Cutting" in silver letters on a green circuit board. The machine emits bright blue light from the laser head.
Laser cutting on a PCB.

Waterjet Cutting

Tools: High-pressure waterjet + abrasive particles (e.g., garnet)

  • How it works:
    • A focused stream of water mixed with abrasives cuts through the board without generating heat.
  • Best for:
    • Thick PCBs (≥3mm) or heat-sensitive components.
  • Pros:
    • No thermal damage to components or materials.
  • Cons:
    • Large, expensive equipment; primarily used in commercial settings.
A waterjet cutting machine is cutting a circuit board, with high - pressure water jetting from the cutting head and obvious water mist around it. There are warning signs on the blue - gray machine.
Waterjet cutting of a PCB.

Pre-Cutting Preparation

  1. Safety Devices:
    • Gear up: N95 mask, safety goggles, and gloves (fiberglass dust is a respiratory hazard).
    • Ventilation: Work in a well-ventilated area or use a fume extractor.
  2. Plan the Cut:
    • Mark the cut line with a permanent marker or CAD software (for CNC/laser).
    • Measure twice to avoid costly mistakes.
  3. Secure the PCB:
    • Use a vise, clamps, or double-sided tape to prevent movement during cutting.
  4. Choose the Right Tool:
    • Match the tool to the board’s thickness and material (e.g., diamond bits for ceramic PCBs).
  5. Test on Scrap:
    • Practice on a spare PCB to refine technique and tool settings.

Step-by-Step Cutting Workflow

For Manual Cutting

  1. Mark the Cut Line
    • Use a ruler or template for straight lines; trace curves with a template or freehand.
  2. Make the Cut
    • For scoring and snapping: Apply firm, even pressure to score the board, then bend gently until it breaks.
    • For rotary tools: Start the tool at low speed, then gradually increase while guiding it along the line.
  3. Deburr and Smooth Edges
    • Sand with 400-1000 grit sandpaper or use a metal file to remove sharp edges.
  4. Clean the Board
    • Wipe with isopropyl alcohol to remove dust and debris.

For CNC Cutting

  1. Design in CAD
    • Use software like Eagle, KiCad, or Fusion 360 to create the cutting path.
  2. Export and Calibrate
    • Save the design as a GERBER file or G-code, then calibrate the machine for material thickness.
  3. Run the Machine
    • Monitor the process to ensure no errors (e.g., bit breakage in CNC).
  4. Inspect and Finish
    • Check for precision; touch up edges if needed.

For Laser Cutting

  1. Power Up Equipment
    • Turn on the air compressor, chiller, voltage stabilizer, and release the emergency stop button. Power on the main controls (start, servo, laser) in sequence.
  2. Import Design & Set Parameters
    • Import the PCB design into software (e.g., LightBurn, AutoCAD). Select and outline the cutting area, then choose/save parameters (power, speed, focus).
  3. Calibrate & Enable Gas Blowing
    • Install the correct nozzle and perform one-click calibration. Confirm results and activate the gas blowing function (nitrogen/compressed air) to clear debris.
  4. Position, Test, and Cut
    • Select the outlined design, position it on the worktable, and run a border test to verify the path. Start the laser cutting process and monitor for accuracy.

How to Choose the Right Method?

Factor Manual Cutting CNC Router Laser Cutting Waterjet Cutting
Cost Low ($10-$50) High ($500+) Very High (Industrial) Very High (Industrial)
Precision Low High Very High High
Ideal Board Thickness Thin (<1.6mm) Thick (1-5mm) Any Thick (3+mm)
Complexity of Cuts Straight lines only Complex shapes Intricate designs Any shape
Safety Risks Low (if careful) Low (enclosed) High (fumes) Low (dust control)

FAQ

Q: Can I cut a PCB with a hacksaw?

A: Yes, but use a fine-toothed blade and clamp the board securely. Expect more manual effort and potential rough edges.

A: Only with industrial-grade lasers designed for PCBs. Hobby lasers pose fire and fume risks; avoid them for fiberglass boards.

A: Use proper clamping, avoid rushing, and choose a tool suited for the board’s thickness. For thick boards, score multiple times before snapping.

A: PCBs contain hazardous materials. Recycle them through e-waste programs or specialized facilities.

Conclusion

Whether you’re wielding a humble utility knife or a state-of-the-art CNC router, the key to successful PCB cutting lies in planning, safety, and matching the tool to the task. Start with simple methods for small projects, then graduate to advanced techniques as your skills and needs grow. Remember: A clean cut isn’t just about aesthetics—it’s about ensuring your electronics function reliably and safely.

Have you tried a unique PCB cutting method? Share your experiences in the comments below!
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Well Done Technology was established in 2008, focus on PCB reverse engineering, PCB assembly, PCB design and manufacturing. Our technical team of more than 20 people includes senior engineers with rich experience.

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