Printed Circuit Board Specialists Since 1965
Reverse Engineering
Reverse engineering is the art of disassembling an existing
product into it's component parts for the purpose of generating documentation aimed at re-manufacture of the product.
As it applies to printed circuit boards in general, it is a process whereby a printed circuit board is stripped
of all it's components to reveal the board itself. We can then regenerate the original design of the board for
the purpose of manufacturing additional boards.
This is particularly useful where the original manufacturer no longer produces or supports a given printed circuit board. There are many older, but very useful electronic products in service today where this may be true. In many instances it would actually be cheaper to generate the tools for fabricating new boards than it would be to replace the entire piece of equipment of which the circuit board is only a part.
CAT inputs the printed circuit board to be reversed engineered into our CAD system through a proprietary method such that it will be exactly like the original printed circuit board. Once input into our CAD system, it would then be possible to further modify this board as easily as one would any original printed circuit board.
Generally, two-layer circuit boards present the best opportunity to be reproduced accurately since we can actually see all copper features. The best multilayer circuit board to reproduce are those with a maximum of four layers with the internal two layers being only ground and power distribution. If your board has more than four layers or if any internal layer has signal lines, we cannot precisely reproduce the internal copper features simply because we can't see them. We can, however, schematically reproduce internal signal lines accurately. To "schematically" reproduce internal signal lines or other copper features means the proper connection will be made, however, the process of reverse engineering denies us the same engineering input the original designer had. If the engineer provided instructions concerning certain components or copper features that required a specific layout be incorporated within the internal layers, we would not have available to us that same instruction. While the board we design from the original may be schematically correct, we cannot guarantee that the copper features on the internal layers will be exactly per the original, thus we cannot guarantee this type board will function exactly as it was originally intended.
The cost for this service is no more than the cost of generating a new printed circuit board, unless it is a multilayer, which will require the extraction of a netlist. And you can obtain all the documentation for a reverse engineered board as is available for new printed circuit boards. We can even generate an intelligent, press-ready schematic for your board!
How we can assist you....
There are several levels at which we can assist you in reproducing your project. The most basic of which is the reproduction of your printed circuit board. These levels can be described as:
1. Printed circuit board reproduction
This involves inputting the copper images of the original board into our CAD system. From this we can extract the files necessary, in the standard RS-274X format, to fabricate the board. These files include:
- all copper image layers
- a silkscreen image
- a solder mask image for either or both sides of the board
- if appropriate, a solder paste image for either or both sides
- a mechanical file depicting the dimensions of the board and certain drill information
- a drill listing in Excellon format
- a drill tool list that shows the drill sizes and their corresponding tool number
- an aperture file
2. Component identification
This is the most difficult part of the process and the most critical. All components must be properly identified, creating a bill of material as an end result. In this process we attempt to determine whether a particular component is currently in production and try to find a data sheet of each unique component. If a component is no longer in production we attempt to determine whether the original manufacturer has made a replacement component. If they have, we determine if the two are pin for pin compatible. If not, we can provide engineering services to design the new component into the original printed circuit board. If the component is not in production, and there is no direct replacement, we will search component brokers who handle obsolete components.
3. Component sourcing
Component identification and sourcing may well decide whether the project can be completed. Sourcing may as well be as difficult a process as identification as we attempt to find vendors that have the components in inventory found in the component identification process. We make every effort to find at least two sources, obtaining pricing information and availability from each vendor. Even if we determine a component is no longer manufactured, we may still be able to find a vendor who has this component in their inventory.
4. Assembly
In using the most current methods of assembly available in our ISO 9001 facility, we provide complete assembly for your project, including surface mount components, wiring harnesses and unit assembly. We can package the finished assembled board to your specifications.
5. Documentation
Should you require documentation of your project, we can provide a finished schematic and any other supporting documentation you may require to include a users manual and a technical manual.
6. Re-Engineering
Many of our clients have an existing product they want modified to perform a function not envisioned in the original. Toward that end, our engineers can modify your product to do virtually anything you want. Once the original printed circuit board is input into our CAD system it may only be a simple matter of placing the modification into the existing design.
What we need from you....
If we are to only reproduce the original printed circuit board, to do our job efficiently and effectively, it is highly desirable that our clients strip the board of all it's components, sending us a bare board. Additionally, one of the prerequisites is our ability to identify all components from a visual perspective so we can create component coupons for importing into the CAD database. Toward that end, if the board does not have a silkscreen showing all components it would be advantageous to provide us with a second, fully assembled board. If this is not available, an accurate scaled drawing of the assembly would help us to recognize the components. It would also be very helpful, but not absolutely necessary, to have a parts list of all components referenced to the board by reference designators and/or a schematic. The success of your project is dependent on how much information is available.
Even if your original board does not have them, our process automatically generates a silkscreen of the components for your board with assigned reference designators and a solder mask, should you require them.
If you have only one board for reproducing, send it to us fully assembled. We can then identify the components before stripping it of all its components.
By offering this service, it is not our intention to assist anyone in reproducing any printed circuit board that is the property of another or in circumventing any law that would protect the rights of any person or company as regards a product they have copyrighted or patented or is otherwise the legal property of any person or company. Everyone requesting this service will be required to sign a document stating their purpose for reverse engineering the printed circuit board to be contracted with CAT, which document absolves CAT, its owner(s), heirs and assigns from all liability for it's part in the reverse engineering of said printed circuit board.
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