Creating Panels for Round Circular PCB's

Most automated Panelize tools are optimized for standardized rectangular PCB shapes. However, FAB 3000 supports hierarchy, nesting, and sub-panels, making it possible to create optimized panels for any PCB shape!

In this tutorial, we'll create an optimized panel for Round Circular PCB's using FAB 3000. After importing your circular PCB design (Gerbers, ODB++, 2581, DXF, etc.) and defining all layer types, please perform the following:

1. Create PCB Rout and Outer Tabs (used to hold PCB in the panel during assembly)

1. Place FAB3000 into NC mode and use: Auto-Rout PCB Border
   • Or from CAM mode: Featured Tools → Auto-Rout PCB Border...
2. Verify the Auto-Rout option values and press OK.
3. Select the PCB outline and the rout will be automatically created.
   • Note: The outline must be closed and continuous. More details here
4. Add Tabs:
   • Use command Add Tab… (or Featured Tools → Add Tab…)
5. Verify options and press OK.
   • Important: In the command window, type R to set tab shape to Rounded for curved edges.
6. Select Tab Locations
   • Select spots that allow the PCB to remain intact throughout manufacturing.
   • For circular PCB's, 4+ tabs are typically required.
   • Note: This tutorial uses randomly placed tabs as a demo. Your PCB manufacturer can recommend best placement for your panel.
7. Save the workspace (Ctrl+S).

2. Panel Setup

1. Create a new panel: File → New → Panel…
2. Review options. Panel setup details here
3. Press OK to create the panel.
   • Note: For circular boards, we will not use the Panelize Wizard. We'll place them manually (see next step).
   • Tip: FAB3000 supports inserting multiple jobs or sub-panels. Learn more

3. Array Circular PCB (Staggered) for Maximum Material Efficiency

1. Use: Insert Job (Job → Insert Job…)
2. Select the circular PCB job to insert.
3. Select Insert Type: Arrayed
4. Enter desired X and Y Counts.
5. Enter a Count larger than needed (we can delete extras later).
6. Enter required Spacing
   • Typically equal to rout diameter, or 3× for added stability.
   • Enable Use Staggered Array.
7. Press OK and choose the insert point.
8. Delete any excess PCB's that exceed the panel boundary.
   • If too few: Undo → Insert Job again → increase count.

4. Finish Panel

Use: Tools → Finish Panel to automatically generate panel elements (fiducials, tooling holes, bars, text labels, etc.). Verify the result, and your panel is complete!

Sub-Panel Creation? A sub-panel is simply the array without using Finish Panel. You can then place multiple sub-panels into a master panel.

Want the Smallest Possible Panel? FAB3000 can auto-shrink the panel to fit what's needed: Tools → Auto-Fit Panel (existing Inserts)

Example Tutorial Movie (no sound):