How to Cut a Circuit Board: Methods, Tools, and Best Practices

Introduction

Cutting a circuit board is a crucial step in PCB prototyping and manufacturing. Whether you need to resize a printed circuit board (PCB) for a specific application or separate multiple PCBs from a panel, precise cutting ensures structural integrity, proper functionality, and a clean finish.

This article will cover different methods of cutting circuit boards, the tools required, step-by-step procedures, safety precautions, and best practices to achieve high-quality results.

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Common Methods for how to cut circuit board

Several techniques can be used to cut a circuit board, depending on the type of PCB material, the level of precision required, and the available tools. Below are the most commonly used methods:

1. Using a PCB Guillotine (Shear Cutter)

A PCB guillotine, also known as a shear cutter, is a specialized tool designed for cutting circuit boards cleanly and efficiently.

✅ Advantages:

• Produces clean, straight cuts with minimal dust
• Fast and efficient for professional PCB fabrication
• Reduces stress and damage to the board

⚠ Disadvantages:

• Limited to straight cuts only
• Not suitable for thick or rigid PCBs

✅ Best For:

• Cutting thin PCBs (FR4, aluminum, or composite materials)
• Mass production and precision cutting

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2. Using a Table Saw or Circular Saw

A table saw with a fine-tooth blade or a circular saw can be used for cutting larger PCBs. These tools are ideal for cutting thick boards or non-standard PCB shapes.

✅ Advantages:

• Can cut through thick and rigid PCB materials
• Provides fast and straight cuts

⚠ Disadvantages:

• May generate excessive dust and debris
• Requires a steady hand or a guide for precision
• Risk of chipping or cracking the PCB

✅ Best For:

• Cutting large PCBs into smaller sections
• Thick PCBs (FR4, metal-core, ceramic)

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3. Using a Dremel Rotary Tool

A Dremel rotary tool equipped with a cutting wheel is a versatile and popular method for cutting circuit boards.

✅ Advantages:

• Can cut curved and intricate shapes
• Suitable for small and custom PCB modifications
• Easy to handle for hobbyists and professionals

⚠ Disadvantages:

• Requires a steady hand for precise cuts
• Generates dust and heat, which can burn the PCB if not careful

✅ Best For:

• Cutting complex shapes and small adjustments
• Modifying PCBs for specific projects

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4. Using a Hand Saw (Jeweler’s Saw or Hacksaw)

A hacksaw or jeweler’s saw with a fine-tooth blade is an affordable and accessible method for cutting PCBs.

✅ Advantages:

• Low cost and easy to use
• Provides controlled, manual cutting

⚠ Disadvantages:

• Time-consuming compared to power tools
• Requires careful handling to avoid jagged edges

✅ Best For:

• DIY PCB cutting
• Prototyping and small-scale projects

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5. Using a CNC Machine (For High Precision)

A CNC (Computer Numerical Control) machine is used for professional PCB manufacturing, ensuring precise and automated cutting.

✅ Advantages:

• Highly accurate cuts
• Can handle complex designs and large production volumes

⚠ Disadvantages:

• Expensive and requires programming knowledge
• Not practical for one-off PCB cutting

✅ Best For:

• Mass production and high-precision PCB cutting
• Cutting intricate circuit board shapes

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Step-by-Step Guide to how to cut circuit board

Follow these steps to ensure a safe and precise PCB cutting process:

Step 1: Gather the Necessary Tools

Depending on the method chosen, you may need:

• A PCB guillotine, rotary tool, hacksaw, table saw, or CNC machine
• Safety gear: Gloves, safety goggles, and a dust mask
• Marking tools: A ruler and a fine-tip marker to outline the cut lines
• Sandpaper or a deburring tool to smooth rough edges

Step 2: Mark the Cutting Line

• Use a ruler and a fine-tip marker to draw precise cutting lines on the PCB surface.
• Double-check measurements to avoid cutting errors.

Step 3: Secure the PCB

• Clamp the PCB to a stable workbench or use a PCB holder to prevent movement.
• If using a Dremel or hacksaw, ensure the PCB is firmly secured.

Step 4: Cut the PCB

• For PCB guillotine: Align the cutting line and press down for a clean cut.
• For table saws or rotary tools: Cut slowly, applying steady pressure to avoid overheating.
• For hacksaws: Move the blade back and forth carefully along the cutting line.

Step 5: Smooth the Edges

• Use sandpaper (200-400 grit) or a deburring tool to remove rough edges.
• For metal-core PCBs, use a file to smooth out burrs.

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Safety Precautions When Cutting Circuit Boards

Cutting PCBs involves risks such as dust inhalation, sharp edges, and tool-related injuries. Follow these safety guidelines:

✔ Wear Safety Goggles: Protect your eyes from flying debris.
✔ Use a Dust Mask: PCB materials, especially fiberglass (FR4), produce hazardous dust.
✔ Work in a Well-Ventilated Area: Avoid inhaling fine PCB particles.
✔ Clamp the PCB Securely: Prevent movement to ensure clean and precise cuts.
✔ Handle Sharp Edges with Care: After cutting, use sandpaper to smooth edges and avoid cuts.
✔ Keep Hands Away from the Blade: When using saws or rotary tools, maintain a safe hand distance.

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Best Practices for Cutting PCBs

• Choose the Right Tool: Select a cutting method based on the PCB thickness and complexity.
• Measure Twice, Cut Once: Avoid mistakes by double-checking the cutting line before proceeding.
• Use Low-Speed Cutting for Heat-Sensitive Boards: Prevent overheating and damage.
• Keep a Clean Workspace: Remove dust and debris to maintain visibility and safety.
• Test on a Scrap PCB First: If using a new tool, practice on a spare board before cutting your actual PCB.

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Conclusion

Cutting a circuit board requires careful planning, the right tools, and proper technique to achieve clean and precise results. Whether using a PCB guillotine for straight cuts, a rotary tool for complex shapes, or a CNC machine for high precision, each method has its advantages and best applications.

By following the step-by-step process, safety precautions, and best practices, you can successfully cut PCBs without damaging the board or compromising performance.

If you’re looking for custom PCB manufacturing, panel cutting, or precision fabrication, Shuoqiang Electronics offers high-quality PCB solutions with fast turnaround times. Contact us today for professional PCB services!
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