Introduction
Printed Circuit Boards (PCBs) are the backbone of modern electronics, providing the necessary connections and support for electronic components. While most PCBs are rectangular or square, there is a growing demand for circular PCBs and other non-standard shapes. These unique shapes are often required for specific applications, such as wearable devices, IoT gadgets, automotive systems, and industrial equipment. Designing non-standard PCBs presents unique challenges, including precise shape definition, component placement, and routing. To address these challenges, engineers need specialized PCB design software that supports non-standard shapes and offers advanced tools for layout and manufacturing. This guide explores the best PCB design software for circular and non-standard PCBs, highlighting their features, benefits, and use cases.
Challenges of Designing Circular and Non-Standard PCBs
1. Shape Definition
- Defining the exact shape of a circular or non-standard PCB requires precise tools and measurements.
- Software must support custom board outlines and allow for easy editing.
2. Component Placement
- Placing components on a non-standard PCB can be challenging due to the irregular shape and limited space.
- Software should offer flexible placement tools and support for curved traces.
3. Routing
- Routing traces on a circular or non-standard PCB requires advanced tools to ensure signal integrity and avoid interference.
- Software should support curved routing and provide design rule checking (DRC) for non-standard shapes.
4. Manufacturing Considerations
- Non-standard PCBs often require specialized manufacturing processes, such as laser cutting or custom tooling.
- Software should generate accurate Gerber files and provide manufacturing output options for non-standard shapes.
5. 3D Visualization
- Visualizing the final product in 3D is crucial for ensuring that the PCB fits within the intended enclosure.
- Software should offer realistic 3D rendering and clearance checking.
Best PCB Design Software for Circular and Non-Standard PCBs
1. Altium Designer
- Key Features:
- Supports custom board outlines and non-standard shapes.
- Advanced routing tools, including curved routing.
- Realistic 3D visualization and clearance checking.
- Comprehensive design rule checking (DRC) for non-standard shapes.
- Integrated with manufacturing output tools for Gerber files and NC drilling.
- Benefits:
- Industry-leading software with robust features for complex designs.
- Seamless integration with other Altium tools for a unified design workflow.
- Use Cases: Ideal for high-end applications such as aerospace, automotive, and industrial equipment.
2. KiCad
- Key Features:
- Open-source software with support for custom board shapes.
- Basic curved routing tools.
- 3D visualization with STEP model support.
- Design rule checking (DRC) and electrical rule checking (ERC).
- Benefits:
- Free and open-source, making it accessible for hobbyists and small businesses.
- Active community support and regular updates.
- Use Cases: Suitable for hobbyists, startups, and educational projects.
3. Eagle (Autodesk)
- Key Features:
- Supports custom board outlines and non-standard shapes.
- Flexible component placement and routing tools.
- 3D visualization with Fusion 360 integration.
- Design rule checking (DRC) and manufacturing output tools.
- Benefits:
- User-friendly interface with a large library of components.
- Integration with Autodesk’s ecosystem for advanced 3D modeling.
- Use Cases: Ideal for small to medium-sized businesses and independent designers.
4. OrCAD (Cadence)
- Key Features:
- Advanced tools for defining custom board shapes.
- Curved routing and differential pair routing.
- Realistic 3D visualization and clearance checking.
- Comprehensive DRC and manufacturing output options.
- Benefits:
- High-performance software with advanced features for complex designs.
- Excellent support for high-speed and mixed-signal designs.
- Use Cases: Suitable for professional designers and large enterprises.
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5. DipTrace
- Key Features:
- Supports custom board outlines and non-standard shapes.
- Flexible component placement and routing tools.
- 3D visualization with STEP model support.
- Design rule checking (DRC) and manufacturing output tools.
- Benefits:
- Affordable software with a user-friendly interface.
- Suitable for both beginners and experienced designers.
- Use Cases: Ideal for small businesses, hobbyists, and educational projects.
6. CircuitStudio (Altium)
- Key Features:
- Supports custom board shapes and non-standard designs.
- Advanced routing tools, including curved routing.
- Realistic 3D visualization and clearance checking.
- Design rule checking (DRC) and manufacturing output tools.
- Benefits:
- Cost-effective alternative to Altium Designer with robust features.
- Seamless integration with Altium’s ecosystem.
- Use Cases: Suitable for small to medium-sized businesses and independent designers.
Key Features to Look for in PCB Design Software for Non-Standard Shapes
1. Custom Board Outlines
- Software should allow users to define custom board outlines using precise measurements and editing tools.
2. Curved Routing
- Support for curved routing is essential for circular and non-standard PCBs to ensure optimal signal integrity.
3. 3D Visualization
- Realistic 3D rendering helps designers visualize the final product and check for mechanical conflicts.
4. Design Rule Checking (DRC)
- Comprehensive DRC ensures that the design meets electrical and manufacturing requirements.
5. Manufacturing Output
- Software should generate accurate Gerber files and provide options for specialized manufacturing processes.
6. Component Libraries
- Access to a large library of components simplifies the design process and ensures compatibility.
7. Ease of Use
- Intuitive interfaces and user-friendly tools make the design process more efficient, especially for beginners.
Step-by-Step Guide to Designing a Circular PCB
Step 1: Define the Board Outline
- Use the software’s board outline tools to define the circular shape with precise measurements.
Step 2: Place Components
- Arrange components on the circular PCB, considering factors such as signal flow and thermal management.
Step 3: Route Traces
- Use curved routing tools to connect components while maintaining signal integrity.
Step 4: Perform Design Rule Checking (DRC)
- Run DRC to ensure the design meets all electrical and manufacturing requirements.
Step 5: Visualize in 3D
- Use 3D visualization tools to check for mechanical conflicts and ensure the PCB fits within the enclosure.
Step 6: Generate Manufacturing Files
- Export Gerber files and other manufacturing outputs for production.
Case Study: Designing a Wearable Device with a Circular PCB
Background
A company developing a wearable fitness tracker needed a circular PCB to fit within the device’s compact, round enclosure. They chose Altium Designer for its advanced features and support for non-standard shapes.
Challenges
- Compact Design: The PCB had to fit within a small, circular enclosure.
- Component Placement: Components needed to be placed efficiently to maximize space.
- Signal Integrity: High-speed signals required careful routing to avoid interference.
Solutions Implemented
- Used Altium Designer: The team leveraged Altium’s custom board outline and curved routing tools.
- Optimized Component Placement: Components were arranged to minimize trace lengths and improve signal integrity.
- 3D Visualization: The design was visualized in 3D to ensure it fit within the enclosure.
- Manufacturing Output: Gerber files were generated for production.
Results
The wearable fitness tracker was successfully designed and manufactured, meeting all performance and size requirements. Altium Designer’s advanced features made it the perfect choice for the project.
Conclusion
Designing circular and non-standard PCBs presents unique challenges, but with the right PCB design software, these challenges can be overcome. Tools like Altium Designer, KiCad, Eagle, OrCAD, DipTrace, and CircuitStudio offer advanced features for defining custom shapes, routing traces, and visualizing designs in 3D. Whether you’re designing a wearable device, an IoT gadget, or an industrial system, these tools provide the functionality and flexibility needed to bring your ideas to life. By choosing the right software and following best practices, you can create high-quality, non-standard PCBs that meet your design requirements and manufacturing needs.