Printed Circuit Boards, or PCBs, are the foundation of almost every modern electronic device. They connect and support components such as resistors, chips, and connectors, allowing electricity to flow through precise pathways. Whether it’s a smartphone, a medical monitor, or defence equipment, each relies on a well-designed PCB to operate reliably.
In this guide, you’ll learn exactly what a PCB board is, how it works, and what it’s used for. We’ll keep the explanations clear and practical so you can understand both the basics and why PCB quality matters in professional manufacturing.
A PCB board, or Printed Circuit Board, connects and supports the electronic components inside a device. It uses copper tracks to carry signals and power between parts, replacing traditional wiring.
The main use of a PCB board is to make electronic systems reliable, compact, and easy to manufacture across industries like medical, defence, and consumer technology.
A Printed Circuit Board, or PCB, is the core platform that connects and holds electronic components inside a device. It provides both mechanical support and electrical connections, allowing current to move between parts in a precise and controlled way.
Most PCBs are made from an insulating material such as fibreglass, coated with thin layers of copper. The copper is etched into narrow pathways called traces, which form the circuit that links components together.
This design replaced older wiring methods that were bulky, unreliable, and hard to reproduce. Because a PCB can manage complex circuits in a small, consistent layout, it has become the foundation for everything from consumer electronics to medical and defence systems.
A PCB works by guiding electrical signals along copper tracks that connect each component on the board. These tracks act like roads, directing electricity to the right parts so the device can perform its functions.
Each board contains layers of conductive copper and non-conductive material. The copper layers carry electrical current, while the insulating layers prevent short circuits. Components such as resistors, capacitors, and integrated circuits are mounted on the board’s surface and linked through soldered connections.
When powered, the current flows through the traces, allowing signals to move between components at precise speeds and strengths. This controlled flow of electricity ensures the device operates safely and consistently.
By designing the circuit layout carefully, engineers can create boards that manage everything from simple lighting controls to more complex systems.
The main use of a PCB board is to connect and control electronic components within a device. It allows electricity to move accurately between parts, making electronic systems reliable, compact, and efficient.
PCB boards are used across almost every industry, including:
By replacing complex wiring with precise copper pathways, PCBs make it possible to build advanced equipment that performs consistently under pressure.
In high-stakes applications, this reliability is critical, which is why Masters & Young is dedicated to designing and manufacturing boards that meet strict Australian and international standards.
PCB boards are built in different ways to meet specific electrical and mechanical needs. The main variations depend on how many conductive layers they have and how signals move across the board.
These board types give engineers flexibility to balance performance, size, and reliability across industries such as medical, defence, and industrial manufacturing.
Every PCB board is made up of several layers that work together to deliver power and communication between components. Each layer has a specific purpose, and the quality of these materials determines how reliable and durable the board will be.
Masters & Young uses materials that meet AS9100D and IPC Class 3 standards, ensuring every board meets the strict quality demands of defence, medical, and industrial projects.
Making a PCB board is a precise and multi-stage process that turns a circuit design into a durable, high-performing electronic platform. Each stage must be carefully managed to ensure signal integrity, component accuracy, and long-term reliability.
The process begins with electronic engineers creating the board layout using CAD software. This layout defines every component location, connection path, and layer configuration. Design tools also check for spacing, trace width, and electrical clearances to prevent short circuits.
At this stage, engineers decide on the number of layers, the board shape, and any mechanical features such as mounting holes or cut-outs. Careful design ensures the finished board performs as expected in its final application.
Once the design is finalised, the fabrication process begins. The copper-clad laminate is cleaned and coated with a light-sensitive film. The circuit pattern is transferred onto the copper using ultraviolet light, and the unwanted copper is etched away to reveal the tracks.
For multi-layer PCBs, individual layers are created first and then laminated together under heat and pressure. Holes known as vias are drilled to connect copper layers vertically. The holes are then plated to form reliable conductive paths between layers.
The surface of the board is cleaned to remove oxidation or debris. A solder mask is applied next, forming the familiar green protective coating. This layer prevents accidental solder bridges between traces and protects the copper from corrosion.
The silkscreen layer adds component labels, polarity markings, and reference indicators. It helps technicians identify where each component belongs during assembly and simplifies future inspection or maintenance.
During assembly, electronic components are mounted on the board using Surface Mount Technology (SMT) or Through-Hole Technology (THT).
Automated pick-and-place machines position each component with precision measured in fractions of a millimetre.
After placement, the board goes through soldering. In reflow soldering, heat melts solder paste applied earlier, bonding each SMT component in place. In wave soldering, molten solder flows under the board, connecting THT components quickly and evenly.
Every PCB undergoes multiple inspections to confirm its reliability before delivery.
At Masters & Young, all boards are built under an AS9100D-certified quality system and inspected to IPC Class 3 standards, which is the highest level of electronic workmanship.
This guarantees that each PCB performs under demanding conditions, from aerospace missions to medical and defence applications.
Every reliable electronic device begins with a well-designed PCB. Whether you need a simple prototype or a complex multi-layer board built to defence standards, Masters & Young can help you turn your concept into a working solution.
Our Brisbane-based team handles the entire process, from design and layout to manufacturing, assembly, and quality assurance, all under AS9100D and IPC Class 3 standards.
We focus on precision, performance, and long-term reliability across defence, aerospace, medical, and industrial applications.
If you’re ready to begin your next project, we’re ready to support you. Contact Masters & Young today to start your PCB process with an experienced Australian team that delivers quality from start to finish.
A PCB (Printed Circuit Board) is the bare board that connects components through copper tracks. A PCBA (Printed Circuit Board Assembly) is the finished product after all components have been mounted and soldered.
Yes, a PCB can often be repaired if the damage is limited. Broken traces can be bridged, and faulty components can be replaced. However, repairs should be done by skilled technicians using proper tools to avoid further damage.
PCBs can range from a single layer to more than 20 layers, depending on the design complexity. Multi-layer boards are common in advanced systems such as communication, defence, and computing equipment.
Quality depends on material selection, precision in copper etching, clean soldering, and thorough testing. Boards built under certified systems like AS9100D and IPC Class 3 provide consistent performance and reliability.
The green colour comes from the solder mask, a protective layer that shields copper from corrosion. Green has become standard because it provides high contrast for visual inspection, but other colours like blue, red, or black are also used.
Sectors such as defence, aerospace, medical, and industrial automation rely on high-performance PCBs. These boards must meet strict environmental, mechanical, and safety standards to operate in critical conditions.
A successful PCB starts long before production. Every stage of the assembly process, from design validation and component sourcing to soldering and QA, affects reliability, cost, and time to market.
If you’re building high-performance electronics for aerospace, defence, medical, or industrial use, you need confidence in how your boards are assembled. Understanding the process helps you reduce rework, speed up delivery, and ensure every unit meets spec, from first prototype to final production.
PCB assembly is the process of turning a fabricated board into a functioning electronic system. It involves mounting and soldering components, either surface-mount, through-hole, or both, in line with the design’s electrical and mechanical requirements.
Where fabrication creates the physical board structure, assembly integrates the active and passive components that give it purpose. This step is critical to performance, reliability, and compliance, especially in industries where failure isn’t an option.
Before assembly begins, engineers review the Gerber files, BOM, and assembly drawings to confirm the design is complete, accurate, and build-ready. Design for Manufacturability (DFM) checks catch issues like mismatched footprints, incorrect pad sizes, or thermal relief problems, all of which can cause hefty delays or board failures downstream.
Once the design is approved, components are sourced based on the BOM. This stage goes beyond availability; it involves matching specifications, packaging types, and confirming whether leaded or lead-free solder is required for compliance. Early procurement planning helps avoid last-minute substitutions and ensures compatibility with the assembly process.
For surface-mount assemblies, solder paste is applied to each pad using a stencil. This step needs tight control because too much or too little paste can cause bridging, tombstoning, or poor joints. Precision here sets the foundation for both electrical performance and mechanical stability.
Automated machines place components onto the pasted board with high speed and accuracy. This includes everything from passives to fine-pitch ICs, QFNs, and BGAs. Proper orientation, spacing, and alignment are critical, especially for high-density or mission-critical assemblies, where rework may not be possible once reflowed.
The placed board then moves through a reflow oven, where temperature profiles are tuned to melt the solder paste and secure each component. Incorrect reflow settings can lead to cold joints, component warping, or incomplete bonds. For complex assemblies, multiple zones and controlled ramp rates will ensure thermal reliability.
If your design includes connectors, high-current parts, or components that need mechanical strength, through-hole components are added next. These are typically soldered using wave or selective soldering. The process must be tuned to avoid overheating adjacent SMT parts or damaging multi-layer boards.
Boards intended for harsh environments, including defence, aerospace, and industrial use, may need added protection. Conformal coating will shield against moisture, dust, and vibration, but it must be compatible with the board material and not interfere with test points or connectors.
Before delivery, every board must be inspected and tested. This may include AOI for SMT parts, X-ray for BGAs, flying probe or bed-of-nails testing, and final functional checks. For IPC Class 2 or Class 3 applications, inspection criteria are stricter, and traceability is often required. These measures ensure that the final product performs reliably under real-world conditions.
A reliable assembly process should support every stage of your product’s lifecycle — not just the first working board.
During prototyping, speed and flexibility are essential. With low-volume builds and evolving designs, this phase is about testing layouts, checking fit and function, and identifying potential issues early.
Quick turnaround times and adaptable sourcing help keep development on track while the design continues to evolve.
As the product moves closer to production, the focus shifts to consistency, control, and compliance. Reflow profiles are locked in, QA procedures are formalised, and every board must meet the same specifications across batches.
In regulated sectors, this often includes IPC Class 2 or Class 3 standards, process validation, and full traceability, all of which become critical as volumes increase.
At Masters & Young, we support this transition through tightly controlled in-house workflows and detailed documentation, ensuring your boards are built to spec, ready for the field, and consistent from the first unit to the thousandth.
A smooth project starts with clean inputs. That means complete Gerber data, an accurate BOM, and clear assembly drawings. Any missing or inconsistent information can lead to misbuilds, delays, or costly rework, especially in dense or regulated designs.
Early DFM input helps prevent common issues before they reach the floor. Things like pad sizing, thermal relief, and component spacing all affect soldering quality and yield. Catching them early saves time and avoids production hold-ups.
Component sourcing also plays a critical role. It’s not just about stock. The right packaging type, leaded or lead-free compatibility, and part lifecycle status all impact the success of the build. Poor substitutions can introduce failures or derail compliance.
Open communication also keeps things aligned. Regular updates, well-documented changes, and clear escalation paths reduce the chance of missteps and help keep the project on track.
A clear, controlled PCB assembly process makes the difference between delays and delivery. Whether you’re building aerospace systems, medical devices, or industrial electronics, the goal is always boards that work reliably, pass inspection, and perform under real-world conditions.
At Masters & Young, we focus on precision assembly, DFM insight, and in-house control, supporting your project from initial design through to production-ready delivery. We’re AS9100D and ISO 9001 certified, JOSCAR-registered, and DISP-listed, making us a trusted supplier for defence and aerospace applications.
With capabilities that span PCB design and manufacturing, SMT assembly, and full PCB assembly services, we help teams move faster, with fewer iterations and fewer surprises.
If you’re planning a new build or refining an existing design, contact us today and build with confidence from the start.
Effective product development requires more than just a good idea. Without thorough market research, even innovative electronic products risk failure. At Masters & Young, we ensure every product aligns precisely with market needs, using detailed research and proven strategies.
Market research involves systematically collecting, analysing, and interpreting information about your market, including potential customers, competitors, and industry trends. It is essential to ensure that innovations address genuine needs and stand out effectively in the marketplace.
At Masters & Young, our Define, Design, and Deliver methodology integrates market research at every stage:
Consider a client who approached us with a concept for a wearable medical device. Through thorough market research, we identified a gap in the current offerings and specific features that users desired. This informed our design process, leading to a product that not only met regulatory standards but also exceeded user expectations.
We utilise a range of tools to gather and analyse market data:
Comprehensive market research is not just a preliminary step; it’s an ongoing process that informs every phase of product development. At Masters & Young, we integrate market insights to ensure that the electronic solutions we design and manufacture are not only innovative but also aligned with market needs and poised for success.
Partner with Masters & Young to leverage our expertise in market research and electronic product development. Contact us today to start your journey from concept to market-ready product.
Our Brisbane facility is equipped with state-of-the-art technology, and we adhere to rigorous quality standards, including ISO certifications, to ensure every product meets the highest benchmarks.
Yes, we offer end-to-end services, from initial concept and design through to manufacturing and testing, ensuring a seamless product development process.
We continuously engage with industry research, attend relevant conferences, and maintain close relationships with clients and partners to stay abreast of market developments.
Our integrated approach, combining thorough market research with innovative design and precise manufacturing, ensures that our clients receive comprehensive solutions tailored to their specific needs.
Masters & Young’s presence at this premier event has been nothing short of exceptional. Our team has been at the forefront, showcasing our cutting-edge electronic solutions and forging valuable connections across the Defence and Aerospace sectors.
Key highlights:
🔹Engaging in insightful discussions with Senior Leaders across the Defence sector, the likes @Amy List from Boeing Defense, Space & Security on the future of Defence electronics in Australia.
🔹Meeting with various government officials and having the opportunity to steer the conversations around local electronics manufacturing
🔹Demonstrating our problem solving skills supported by our state-of-the-art SMT & PTH Technology capabilities.
🔹Using this as a foundational platform to build relationships, and discuss exciting new business opportunities with so many other organisations looking for Electronics Engineering support.
The conversations we had and the partnerships we have already initiated underscore our innovative spirit that drives our Define, Design, and Deliver methodology.
We’re eager and excited by our new collaborations that will push the boundaries of electronic engineering in Defence and beyond, we’re more committed than ever to transforming these new ideas into reality.
If you missed us at Avalon it’s never too late to connect! Please reach out to discuss how our expertise in electronic product design, research, manufacturing, and testing can support and your next project.
Let’s innovate together and shape the future of Defence and Aerospace electronics.
