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Printing with a laser printer on a PCB laminate

lukasku 61380 111

TL;DR

  • A modified Pantum 2502 laser printer prints directly onto PCB laminate.
  • The modification follows a factory-style Instructables guide, and the cheaper Pantum 2502 without Wi‑Fi uses the same parts as the 2502W.
  • The laser approach replaces the inkjet-and-toner hybrid method and lets boards be prepared quickly from computer designs.
  • The main drawback is expensive toner, but the result was satisfying and easier than "iron methods" with less demanding degreasing.
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Treść została przetłumaczona polish » english Zobacz oryginalną wersję tematu
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  • #91 16873315
    silelis
    Level 12  
    Posts: 114
    Rate: 24
    Just. I forgot to make a hole. :D

    Do I understand correctly that after inserting the tray into the guides, until they touch the toner rolls, I mark the end of the sensor and from it down the tray (about 2 "below) do I make a hole ??
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  • #92 16873331
    lukasku
    Level 10  
    Posts: 95
    Rate: 43
    I do not remember exactly, but I am sure it is measured from touching the sheet to the rollers and as far as I remember (but I'm not sure if 3cm from the sensor tip selection, you need to check it) ~ 5mm from the edge. Make a hole of 0.5mm and if you do not hit it you can enlarge it to 0.8 or 1mm.
    I will write how it works so that you know where to look for a possible error. You have three sensors in the printer, named in the tutorial mfps, pis, es and npis is an additional, because these original three sensors are removed from the printer. All three sensors must go through the specified time for all three sensors. The most important is pis. When the uC board starts, it switches mfps programmatically, after ~ 500-550ms (time between the sheet metal position on the drum and the hole position in the sheet on the photoresist), when the hole in the sheet is on the photoresist (npis), the UC switches on, counting from the writing ~ ms delay and printing starts. In other words, the most important thing is to write, since it starts printing, mfps and es are actually paper jam sensors.
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  • #93 16873337
    silelis
    Level 12  
    Posts: 114
    Rate: 24
    I'll get home, I'll make it. Sure, that's it. :D

    And from a different barrel. the movie you uploaded, what is the printer and are you going to do a tutorial for this?
  • #94 16873360
    lukasku
    Level 10  
    Posts: 95
    Rate: 43
    Lexmark e460, maybe I'll do a tutorial, how I can find a moment of time.
  • #95 16873596
    rsv6
    Level 13  
    Posts: 1713
    Rate: 282
    I wonder if there is such a thing as a shower printer
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  • #96 16873613
    silelis
    Level 12  
    Posts: 114
    Rate: 24
    3d printers are probably sprayed? And every inkjet works on this principle. BWT: I used to think about making tiles with a UV inkjet printer. There are those that can print on flat sheets, but this is a very expensive case .
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  • #97 16873617
    lukasku
    Level 10  
    Posts: 95
    Rate: 43
    rsv6 wrote:
    I wonder if there is anything like a shower printer

    The only thing that comes to mind is an inkjet printer converted :D I also have one. It works great too, but the problem is drying up the carcass. All the time you have to remember to print something from time to time, which was just my reason for changing to a laser.
  • #98 16875143
    silelis
    Level 12  
    Posts: 114
    Rate: 24
    OK. Now I have a real turn signal - once it prints, it does not print once.

    I made a hole in the plate. 1 mm hole, about 5 cm below the NPIS sensor, 2 mm from the edge.

    I am waiting for the buzzer to stop buzzing (I am buzzer for 5 seconds, not 3.5) and sometimes it will print and sometimes it will not.

    So actually NPIS does not fit in the window.

    I wonder if 5 cm is too far away and it is not better that the hole is at max 10 mm to the bottom edge of NPIS ??
  • #99 16875156
    rsv6
    Level 13  
    Posts: 1713
    Rate: 282
    Well, but the ink in the usual printer is probably the middle of the season.
  • #100 16875199
    silelis
    Level 12  
    Posts: 114
    Rate: 24
    rsv6 wrote:
    No, but the ink in the usual printer is probably the middle of the issue.
    < br />

    Not so much podtrawi as "dissolve". Therefore, it would be best if the UV ink is more durable for water.
  • #101 16875420
    lukasku
    Level 10  
    Posts: 95
    Rate: 43
    silelis wrote:
    Okay. Now I have a real turn signal - once it prints, it does not print once.

    I made a hole in the plate. 1 mm hole, about 5 cm below the NPIS sensor, 2 mm from the edge.

    I am waiting for the buzzer to stop buzzing (I am buzzer for 5 seconds, not 3.5) and sometimes it will print and sometimes it will not.

    So actually NPIS does not fit in the window.

    I wonder if 5 cm is too far away and it is not better that the hole is at max 10 mm to the lower edge of NPIS ??

    Drill a hole earlier and see, sometimes you need to figure it out :)

    rsv6 wrote:
    No, but the ink in the usual printer is probably the middle of the issue.
    < br /> It worked best with me, you print with water-resistant ink, after drying you slightly dry and sprinkle toner. Excess toner is removed with a gentle brush and heated. It goes nicely.
  • #102 16875595
    rsv6
    Level 13  
    Posts: 1713
    Rate: 282
    I heard that the best pcb come from thermo transfer from printing on color newspapers
  • #103 16875664
    yogi009
    Level 43  
    Posts: 14667
    Help: 848
    Rate: 2646
    rsv6 wrote:
    I've heard that the best pcb comes out of thermo transfer from printing on color newspapers


    I have other experiences.
  • #104 16876501
    398216 Usunięty
    Level 43  
    Posts: 34016
    Help: 3914
    Rate: 9189
    yogi009 wrote:
    rsv6 wrote:
    I heard that the best pcb come from thermo transfer from printing on color newspapers


    I have different experiences.

    Perhaps you have used the wrong paper (newspapers) - it must be slippery and thin, then it goes really elegant - much better than on chalk paper.
    It is also important what paints the printing house uses - some pages of newspapers with multicolored pictures are not good, while when there is only one - two colors (print, for example) there are no problems.
  • #105 16876518
    yogi009
    Level 43  
    Posts: 14667
    Help: 848
    Rate: 2646
    120g chalk paper, optimal printout.
  • #106 16876529
    Freddy
    Level 43  
    Posts: 19997
    Help: 1394
    Rate: 2806
    The "slippery paper" (covered with silicon, probably) from the stickers also gives a good effect.
  • #107 16876682
    silelis
    Level 12  
    Posts: 114
    Rate: 24
    silelis wrote:
    Okay. Now I have a real turn signal - once it prints, it does not print once.
    I made a hole in the plate. 1 mm hole, about 5 cm below the NPIS sensor, 2 mm from the edge.
    I am waiting for the buzzer to stop buzzing (I am buzzer for 5 seconds, not 3.5) and sometimes it will print and sometimes it will not.
    So actually NPIS does not fit in the window.
    I wonder if 5 cm is too far away and it is not better that the hole is at max 10 mm to the lower edge of NPIS ??


    I think I've found a solution. The original tutorial says:

    Quote:
    Remove the carrier. Now, a small hole in the carrier, located about 3mm. I used a .026 inch drill.

    And according to it, I made a hole 5 cm below the sensor. For this reason, sometimes I was located, and sometimes exceeded the "time window". I made a second hole about 7 mm below the sensor and everything works now, but the tests will show.
  • #108 16968934
    silelis
    Level 12  
    Posts: 114
    Rate: 24
    Well, I'll praise you. After many attempts and something came out. I do not know why Eagle prints very poorly. The effects are just like in Eagle will print to PDF and then scream for the printer.
    No paths. The thinner they are, the better the blackening, and the thick ones do not come out very well. In the picture, the path is 8 mils, and unfortunately [with these dimensions some are already drained, so 10 mils is probably the maximum of this technology.
    Printing with a laser printer on a PCB laminate

    Printing with a laser printer on a PCB laminate

    When printing this second tile, I "killed" the drum. :D
  • #109 16970352
    lukasku
    Level 10  
    Posts: 95
    Rate: 43
    I did 8 or even 7 mils between pads and it came out pretty. It is true that this "print wizard" in the Eagle is some kind of lip, especially with large tiles, strange things do, sometimes it also does not keep dimensions when moving away from the margins, etc., hence combines when printing with older versions of EAGL or PDF. The second thing is drums, and massaging the tiles. One of the drums, or toners, some "prefer" a perfectly smooth surface, other 400/500 paper. As for the amount of toner, try printing on a sheet, how it will print perfectly on a piece of paper, then print on a plate.
  • #110 16970930
    silelis
    Level 12  
    Posts: 114
    Rate: 24
    I do not stick to the card.

    Can you paste the settings of the "print quality" tab from your PC ??
  • #111 18268504
    Vitorbnc
    Level 1  
    Posts: 1
    Greetings to everyone! I'm new here.

    I recently bought a Lexmark E460DN in hope of building a PCB direct printing setup based on mlerman's instructable.
    I know this is an old thread but I'm interested in @lukasku modification. Could you or someone else provide some hint about modifying this specific printer?

    Thanks!
  • #112 18276685
    silelis
    Level 12  
    Posts: 114
    Rate: 24
    Unfortunately, I have e240, but from experience I will say that making double-sided inserts is problematic (the issue of positioning, you need to repeat the printing of the second page several times) and now I am leaning towards a CNC milling machine.
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Topic summary

✨ The discussion revolves around the challenges and techniques of printing directly on PCB laminates using modified laser printers, particularly the Pantum and Lexmark models. Users share experiences with various methods, including the use of silicone spray to enhance toner adhesion and the hybrid approach of combining inkjet printing with toner transfer. Key issues include the need for precise laminate preparation, the durability of the toner, and the potential wear on printer components. Participants also explore the feasibility of using UV inkjet printers and CNC milling for PCB fabrication, highlighting the importance of print quality and the impact of different toners and papers on the final results.
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FAQ

TL;DR: Pantum P2500 drum replacements cost PLN 180 (~€40) [Elektroda, lukasku, post #16774910]; “after 30 prints durability looks good” [Elektroda, lukasku, post #16628484] Use silicone spray, 0.8–1 mm registration holes, and correct sensor timing to get sub-10 mil tracks quickly.

Why it matters: Direct-laser printing slashes one-off PCB build time from hours to minutes without messy irons.

Quick Facts

• Typical track width achievable: 7–10 mil (0.18–0.25 mm) [Elektroda, lukasku, post #16970352] • Replacement OPC drum costs: Pantum P2500 ≈ PLN 180; Lexmark E460 ≈ PLN 15 [Elektroda, lukasku, post #16774910] • Silicone spray brand tested: K2 Perfect SIL, thin wiped layer [Elektroda, lukasku, post #16630866] • Tray registration hole: 0.8–1 mm, ≤10 mm below NPIS sensor [Elektroda, silelis, post #16876682] • Heating for toner hardening: 180 °C for 3 min or acetone vapour 30 s [Elektroda, lukasku, post #16740784]

What is the correct registration-hole position for Lexmark E260?

Drill a 0.8–1 mm hole about 7–10 mm downstream of the NPIS sensor and 2–5 mm from the sheet edge; farther holes miss the 500–550 ms timing window and toner never fires [Elektroda, silelis, post #16876682]

How do I run the direct-laser printing cycle?

  1. Clean, lightly sand, degrease copper; wipe on thin silicone film.
  2. Feed laminate through modified printer; ensure 180 °C fuser is disabled.
  3. Bake board at 180 °C for 3 min or expose to acetone vapour 30 s to harden toner [Elektroda, lukasku, post #16740784]

What does the full cost of ownership look like?

Converted Pantum setup: used printer PLN 100 + drum PLN 180 + ATtiny + misc ≈ PLN 320 (≈€70). Lexmark route: printer PLN 120, drum PLN 15, total ≈ PLN 150 (≈€33) [Elektroda, lukasku, post #16774910] One commercial 1 m² digital photoplot costs PLN 30–40 [Elektroda, wada, post #16631587], so the break-even is 4–5 prototype runs.
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