Can I have my printed circuit boards in a choice of colours?

Yes, you can choose from a range of solder mask colours for your PCBs. Whether you prefer the classic green, or something different like red, blue, black, or even white, we can accommodate your preference while maintaining the same high standards of quality and reliability.

Can I get my printed circuit boards in different thicknesses?

Yes, we offer a range of PCB thicknesses to suit different designs and applications. Standard options range from 0.4mm to 1.6mm in 0.2mm increments, with additional options at 2mm, 2.4mm, and 3.2mm. The most common thickness for multilayer boards is 1.6mm, but we regularly work with boards from 0.5mm up to 3.2mm.If you’re unsure which thickness is right for your project, just get in touch – we’re happy to offer advice and help you choose the best option.

What is the smallest PCB size I can have?

PCBs can be made in a wide range of shapes and sizes to suit your project. The smallest we’ve manufactured is just 5mm square, for a compact medical device.The final PCB size will depend on factors such as design complexity, number of layers, component weight, and the intended application. We also take manufacturing requirements into account, including tool borders and panel strength, especially for larger or irregularly shaped boards. Small or uniquely shaped PCBs can be routed precisely and supplied in panels for easier handling.If you’re unsure about size or design options, just get in touch - we’re happy to help you find the best solution.

Can you do complex curved outlines on your printed circuit boards?

Yes, we can manufacture custom-shaped PCBs, including complex curves and non-standard edges, ideal for designs that need to fit into compact or irregular spaces. Simply send us your design files or outline requirements, and we’ll handle the rest. If you need guidance on the design, our team is happy to advise.

Can I have my printed circuit boards left in a panel for assembly?

Yes, we can supply your PCBs in a panelised format, which is ideal for automated assembly and easier handling during production. Simply let us know your panel requirements, and we’ll prepare them to suit your process. If you prefer, we can also handle the assembly in-house, helping you streamline the entire project from design through to delivery.

PCB Manufacturing

Advanced PCB fabrication from prototype to production. Precision CNC drilling, multilayer lamination, and rigorous testing—delivering high-quality printed circuit boards with fast turnaround times.

ISO 9001-2015 certified. 40+ years UK manufacturing experience.

Our Manufacturing Capabilities

Complete PCB Fabrication

Single-sided, double-sided, and multilayer PCB manufacture
Flexible and rigid circuit boards
Prototype PCB and small batch production
High-volume manufacturing with consistent quality
Reverse engineering services

Advanced Technology

Precision CNC drilling with laser verification
Four-head flying probe testing for bare board validation
Shadow line carbon plating for perfect hole connections
ISO 9001-2015 certified production control systems

UK PCB Manufacturer

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Everything manufactured in-house at our Baldock, Hertfordshire facility. Complete traceability and technical support from our designers and engineers.

Providing bespoke PCB services for over 40 years!

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The PCB Manufacturing Process

1. Design and Gerber Files

Your PCB design files form the blueprint for fabrication. We accept standard Gerber format and extended Gerber (RS-274X). Our design for manufacture review ensures your design is optimised for the production process.

2. Inner Layer Preparation

Copper foil is laminated onto substrate material. UV light exposure through photo-sensitive film transfers your circuit pattern onto each inner layer. Areas meant to harden receive a blast of UV light, protecting the desired copper traces. Unexposed resist is washed away with an alkaline solution.

3. Etching

Unwanted copper is chemically removed, leaving only your circuit traces. The resist covering the copper is stripped, revealing exposed copper in the exact pattern specified by your PCB design.

4. Layer Alignment and Lamination

For multilayer PCB construction, inner layers are precisely aligned using registration pins. The layers are placed together with prepreg (pre-impregnated laminate) material between each copper layer. Heat and pressure in the laminate press bond everything into a solid board.

5. Precision Drilling

Our CNC drilling system creates holes with micron-level accuracy. The auto-tool change head selects the correct drill bit for each hole diameter, adjusting speeds for optimal precision. Laser verification checks diameter, length, and positional accuracy on every hole drilled.

6. Plating Process

Shadow line plating coats each hole with carbon before the copper plating process begins, guaranteeing perfect electrical connection from one side of the board to the other. Surface finishes include electroless nickel immersion gold (ENIG) for superior solderability when required.

7. Solder Mask Application

Solder mask protects copper traces from oxidation and prevents solder bridges during PCB assembly. This thin layer of protective coating is applied to all outer layers of the PCB, with openings only where components will be soldered.

8. Surface Finish and Silkscreen

Final surface treatment prepares component pads for assembly. Reference designators, component outlines, and other markings are printed onto the board surface for assembly guidance.

9. Testing and Profiling

Every finished PCB undergoes rigorous inspection at multiple process steps. Our four-head flying probe tester validates electrical continuity across all connections. Final profiling cuts boards to exact shape, including complex curved outlines when required.

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Quality Control Throughout Production

ISO 9001-2015 Certified
Our production control systems monitor every stage of the board manufacturing process to ensure consistency and reliability across prototype and production runs.

Rigorous Testing

Flying probe electrical testing on bare boards
Visual inspection at every production stage
Dimensional verification to design specifications
Full traceability from raw materials to finished product

Expert Team
Experienced technicians and engineers guide you through the PCB design process, ensuring your boards meet exact specifications. We can assist with design for manufacture analysis to optimise your PCB for the fabrication process.

PCB Specifications

Thickness Options
Standard: 0.4mm to 1.6mm (0.2mm increments)
Heavy-duty: 2mm, 2.4mm, 3.2mm
Most common: 1.6mm for multilayer boards

Size Range
Smallest manufactured: 5mm square (medical/aerospace applications)
Custom shapes and complex curved outlines available
Panels supplied for assembly when required

Layer Count
Single-sided to complex multilayer configurations

Solder Mask Colours
Green (standard), blue, red, black, white

Copper Weight
Standard through to heavy copper for high-current applications

From Prototype PCB to Production

Fast Prototype Turnaround
Quick validation of your PCB design before committing to production. Small quantities with the same quality standards as full production runs.

Scalable Production
Seamless transition from prototype printed circuit boards to high-volume manufacturing. Our production process ensures every board matches your prototype specifications exactly.

Panelised Boards
PCBs supplied in panel format for automated assembly. Ideal for efficient production and assembly workflows.

Why Choose ABL Circuits?

Complete In-House Control
From PCB fabrication through to assembly—everything under one roof. No outsourcing, complete quality control, faster turnaround times.

UK Manufacturing
Local PCB production with responsive technical support. Fast turnaround without overseas shipping delays. Support British manufacturing.

Design Support
Our team assists with PCB design, design for manufacture analysis, and technical specifications. We help ensure your design is optimised for the manufacturing process before production begins.

Manufacturing Excellence
State-of-the-art equipment combined with decades of experience. Precision results on every board, from prototype to high-volume production.

Competitive Pricing
Direct from manufacturer pricing with no middlemen. UK quality without premium pricing.

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Key Differences Between SMT and THT Assembly

PCB assembly uses two main techniques:

Surface Mount Technology (SMT)

SMT components are soldered directly onto the board’s surface, offering:

Faster, automated assembly
Often using Pick and Place machines.

Smaller, cost-effective components
Ideal for compact, high-density designs.

Pre Build CheckFaster, automated assembly
Connections may be weaker under stress.

Through-Hole Technology (THT)

THT involves inserting component leads through drilled holes for a stronger connection:

More durable and reliable
Ideal for high-vibration or high-power applications.

Longer production times
Additional drilling and soldering steps required.

Larger, pricier components
Due to lead-based design and extra material.

Looking for a bespoke manufacturing solution?
See how ABL Circuits can help you today:

Call us now on 01462 894 312

Quick Quote

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PCB Manufacturing