How to Design and Etch Your Own PCBs Using KiCad and Ferric Chloride

Got some new boards we would like to prototype, so I'm sharing the first time I had ever etched a board, experience was little and tools were scarce, below the steps are summarized, We made these for a Solar Demonstrator Unit at Tshwane University.(2016)

Pulled from an actual report I had to make, let's dive into it.

Designing and etching your own PCBs at home can be an incredibly rewarding process. Whether you're prototyping or just want a hands-on experience with circuit design, this guide will walk you through how to design your PCB in KiCad and etch it using ferric chloride.

What You’ll Need

Software:

• KiCad (Free PCB design tool)

Hardware & Materials:

• Laser printer or inkjet printer with transfer paper

• Copper-clad board (FR1/FR4)

• Ferric chloride solution

• Iron (for toner transfer method)

• Plastic container for etching

• Drill for component holes

• Gloves, safety glasses, and good ventilation

Step 1: Designing the Circuit in KiCad

1. Install KiCadDownload and install the latest version of KiCad from the official site.

2. Schematic Design

   • Open KiCad and create a new project.

   • Use the schematic editor to place components and wire them together.

   • Annotate your components and assign footprints.

3. PCB Layout

   • Switch to the PCB editor.

   • Import the netlist from the schematic.

   • Arrange components and route traces manually or using the autorouter.

4. Export the PCB Artwork

   • Go to Plot, select PDF or Gerber depending on your method.

   • Make sure to mirror the top layer if using toner transfer.

   • Print onto glossy photo paper or special toner transfer paper.

Step 2: Transferring the PCB Design to Copper

1. Clean the Copper Board

   • Scrub with fine steel wool or abrasive sponge.

   • Wash and dry thoroughly.

2. Transfer the Toner

   • Place the printed artwork (toner side down) on the copper board.

   • Press using a hot iron (around 150–180°C) for ~5 minutes with firm pressure.

   • Allow to cool, then soak in water and peel off the paper gently.

Step 3: Etching the PCB with Ferric Chloride

1. Prepare Your Etching Bath

   • Pour ferric chloride into a plastic container. Do NOT use metal.

   • Warm the solution slightly (~40°C) for faster results (optional).

2. Etch the PCB

   • Submerge the board and agitate gently every few minutes.

   • The etching process can take 15–30 minutes depending on temperature and concentration.

   • Once the exposed copper is gone, remove the board with tongs.

3. Rinse and Clean

   • Rinse the board under running water.

   • Use acetone or nail polish remover to remove the toner and expose the copper traces.

Step 4: Drilling and Finishing Touches

• Use a small drill press or Dremel to make holes for through-hole components.

• Optionally, apply solder mask or tin the traces.

• You now have a homemade, ready-to-use PCB!

Final Thoughts

DIY PCB fabrication is a great way to understand electronics from the ground up. Tools like KiCad make professional-level design accessible, while ferric chloride etching offers a low-cost, hands-on way to bring your designs to life.

If you’d like a walkthrough with images or a video tutorial, let us know—we’re planning to share more hands-on electronics guides soon!