Send one board. Get Gerber, BOM and the schematic back.
PCB copy and PCB reverse engineering from 1 to 32 layers, with a prototype we have already built and tested. If the MCU on the board is locked, we read that out too.
16 years reverse engineering20,000+ boards deliveredNDA before you ship anythingReply within 24 hours
What Is PCB Copy and Why Do Engineers Need It?
PCB copy is the reverse-engineering process that extracts a complete set of manufacturing data—Gerber files, bill of materials (BOM), and schematic—from an existing physical circuit board. Engineers order a PCB copy when the original design files are lost, the OEM no longer supports the product, or a legacy board must be replicated for continued production without redesigning from scratch.
Our lab handles boards from simple 2-layer FR-4 designs up to complex 32-layer HDI stackups. A typical PCB copy project delivers production-ready output in 5–8 working days for boards under 8 layers, with more complex jobs running 10–20 days depending on layer count, component density, and whether firmware recovery is involved.
How Does a PCB Copy Project Work?
Every PCB copy follows a structured workflow. Skipping steps causes dimensional errors, incorrect net assignments, or missed buried vias—problems that only surface after fabrication. Here is the sequence our engineers follow:
Step 1 — Intake and Feasibility Review
You ship or upload high-resolution photos of the board. We assess layer count (via edge inspection or cross-section), component density, and any conformal coating or potting that must be removed before scanning. Boards with conformal coating add 1–2 days for chemical or plasma stripping.
Step 2 — Layer-by-Layer Imaging
Outer layers are scanned optically at 2400+ DPI. Inner layers require controlled delamination or precision micro-milling to expose each copper plane. For a 4-layer board this means two delamination cycles; a 12-layer board needs eleven. Each exposed layer is photographed, aligned to fiducials, and digitized into vector artwork.
Step 3 — Netlist Extraction and Schematic Capture
Our CAD team traces every net from pad to pad, cross-referencing against the physical board with continuity testing. The result is a verified netlist that feeds into schematic capture. For boards with BGA packages (0.5 mm pitch or finer), X-ray imaging confirms via-in-pad routing beneath the package.
Step 4 — BOM Generation
Every component is identified by package, marking code, and measured value. Passives are verified on an LCR meter; ICs are matched to datasheets. Where parts are obsolete, we flag recommended cross-references so you can source without delay.
Step 5 — Output, Review, and Sign-Off
You receive the complete file package. We walk you through a design-review checklist and correct any issues before you send files to fabrication. Learn more about the exact file formats we deliver.
What Files Do You Get From a PCB Copy?
Deliverable
Format
Notes
Gerber files (all layers)
RS-274X / Gerber X2
Includes drill files (Excellon), soldermask, silkscreen, paste
Schematic
PDF + editable (Altium / KiCad / OrCAD on request)
Pricing is project-specific, but the dominant cost drivers are predictable. Here is what moves the number up or down:
Layer count: A 2-layer board typically starts around $300–$500. An 8-layer board runs $800–$1,500. Beyond 12 layers, expect $1,500–$4,000+ depending on density.
Component count: A 50-component board is straightforward; a 1,200-component telecom card requires significantly more BOM and schematic effort.
BGA / fine-pitch ICs: X-ray imaging adds cost but is non-negotiable for correct via mapping under 0.4–0.8 mm pitch BGAs.
Impedance-controlled stackups: Boards with differential pairs or controlled-impedance traces require stackup reverse-solving—our engineers back-calculate dielectric constants and trace geometry to match the original impedance targets within ±5–8 %. See our page on impedance-controlled PCB copy.
IC unlock / firmware extraction: If the board contains a programmed MCU whose firmware must be read out, this is a separate service priced by chip family and protection level.
Turnaround: Standard is 5–15 working days. Rush (3–5 days) adds 30–50 %.
For detailed pricing ranges by layer count and complexity tier, visit our PCB copy pricing page.
Get an Instant Estimate
Use the calculator below to generate a ballpark quote based on your board’s layer count, dimensions, and component count. The estimate is a starting point—final pricing is confirmed after our engineers review your board or photos.
PCB manufacturing
Instant PCB Manufacturing Cost Estimator
Change any parameter and watch the price move. The point is not the exact number, it is seeing which choices actually drive your cost.
mm
mm
pcs
Estimated price per board
Estimated order total
One-time tooling
Recurring board cost
Area per boarddm²
Effective price per dm²
How this is calculated
The model is the one every fabricator uses underneath their quoting engine: a one-time tooling charge that does not care how many boards you order, plus a recurring cost driven by finished area, layer count and process options, discounted as quantity climbs.
Three things follow from that structure and they are worth more than the number itself. First, at low quantity you are mostly buying tooling, so ten boards rarely costs a tenth of a hundred. Second, layer count is the single most expensive parameter, because each added pair means another lamination cycle, another drill and plate sequence, and another chance to scrap the panel. Third, options that sound minor are not: a 24-hour turn can nearly double the price, since the shop has to break an existing schedule to fit you in.
These are indicative figures for a volume Asian fabricator on a standard process. They are not a quotation. Send your Gerbers to a real supplier before committing to a budget.
Board Types We Handle for PCB Copy
Our lab is equipped for the full spectrum of PCB construction types. Here is a representative sample:
Thermal via pattern, dielectric thickness measurement
5–7 days
Explore specific layer-count pages for detailed stackup and recovery notes: 4-layer PCB copy, 12-layer PCB copy, or boards up to 32 layers.
IC Unlock and Firmware Recovery
Many boards contain microcontrollers with read-protected firmware. A PCB copy without the firmware is an empty shell—the board powers on but does nothing. Our IC unlock service extracts the program code from protected MCUs (STM32, PIC, ATmega, Renesas, NXP, and others) so the copied board can function identically to the original.
Authorization requirement: We perform firmware readout only for clients who demonstrate ownership or legal authorization over the target design. Every project is covered by an NDA. This protects both parties and ensures the work is used for legitimate purposes—legacy maintenance, second-sourcing your own product, or disaster recovery.
Quality Assurance — How We Verify a PCB Copy
A PCB copy is only useful if the resulting board works. Our QA process catches errors before fabrication:
Optical overlay: Digitized artwork is overlaid on the original board scan at 1:1 scale. Deviations > 1 mil are flagged and corrected.
DRC (Design Rule Check): Gerber files are run through DRC against IPC-2221B spacing and width rules for the board’s voltage class.
Netlist comparison: The extracted netlist is compared against physical continuity measurements. Any mismatch triggers re-trace of the affected net.
Cross-section verification (multilayer): On boards ≥ 6 layers, we cross-section at least two locations to confirm via type (through, blind, buried) and dielectric thickness.
First-article test: On clone/assembly projects, the first assembled board undergoes functional testing before batch production.
Common Failure Modes in PCB Copy (and How We Avoid Them)
Missed Internal Plane Splits
Power and ground planes often have splits for voltage domains. Low-resolution imaging or careless tracing merges these domains, causing shorts. Our engineers trace every split edge and verify with impedance measurement.
Incorrect Via Types
A via that looks like a through-hole on the surface may actually be a blind via terminating at layer 3. X-ray and cross-section confirm the span. Getting this wrong means the fab drills through layers that should remain intact.
Component Value Drift
Desoldered resistors and capacitors shift in value. We measure passives in-circuit where possible and cross-reference with datasheet-typical values for the circuit topology (e.g., a 10 kΩ pull-up on an I²C line is unlikely to be 9.87 kΩ—it’s a standard value drifted by heat).
Who Orders a PCB Copy?
OEMs with lost design data — fire, server crash, departed engineer, or acquisition without IP transfer.
Repair shops — need bare boards to repair equipment whose manufacturer is defunct.
Contract manufacturers — customer supplies a sample board, not files; CM needs Gerbers to quote fabrication.
R&D teams — benchmarking a competitor’s layout topology (within legal bounds) or studying a reference design.
Military / aerospace sustainment — DMSMS (diminishing manufacturing sources) programs require exact-form-fit-function board replicas for fielded systems.
How many boards do you need to perform a PCB copy?
One board is sufficient for most projects. For destructive inner-layer extraction on multilayer boards, we consume one sample. If you need the original board returned intact, send two—one for imaging, one preserved. On 1–2 layer boards, non-destructive scanning is standard and your board is returned undamaged.
Can you copy a board if some components are missing?
Yes. Missing components leave solder footprints that reveal package size and pad geometry. We identify the part from the circuit context, silkscreen markings, and surrounding topology. If a critical IC is missing and its exact part number cannot be determined, we flag it in the BOM with our best-match recommendation and a note for you to confirm.
Is PCB copy legal?
PCB copy for your own products, legacy maintenance, or authorized recovery is legal in most jurisdictions. We require clients to confirm ownership or authorization before starting work. All projects are covered by mutual NDA. We do not accept projects that target active third-party IP without documented licensing rights.
What is the minimum trace width and spacing you can resolve?
Our optical and X-ray imaging resolves features down to 2 mil (0.05 mm) trace and 2 mil space. For ultra-fine HDI boards with 1.5 mil features, we use SEM-assisted imaging on critical areas. The practical limit depends on copper weight and etch quality of the original board.
Do you also fabricate and assemble the copied board?
Yes. We offer end-to-end PCB clone service: reverse engineering → fabrication → component sourcing → SMT/THT assembly → functional test. You can also take the files and use your own fab—we deliver in standard formats accepted by any manufacturer worldwide.
Main service
PCB copy, from one board to a fab-ready file set
Most projects start with a single physical board and no files anywhere in the company. This is the service that fixes that, and it is what we do most of.
PCB copy · board cloning
1 to 32 layers, including the boards other shops send back
Blind and buried vias, laser microvia HDI, RF microstrip, ceramic and flex substrates, fine pitch BGA. Every net is checked electrically against your sample, then a prototype is built and tested before any file leaves the building.
Protected MCU, ARM, CPLD and FPGA parts read out through software attack, fault injection, side channel analysis or invasive microprobing, whichever the die calls for. Our database covers 5000+ models.
Schematic recovery for boards you need to change, not just repeat. Netlist extraction verified connection by connection, every part identified with a real manufacturer number, and editable source your own engineers can open.
Schematic + BOM, from$400
Prototype build and test, from$600
Typical lead time7-15 days
You receive: schematic, netlist, BOM with MPN, source files
Send photos of the board or the chip marking. Within 24 hours you know whether it can be done, how long, and what it costs.
NDA, then ship the sample
We sign first, you ship second. Courier details and our full registered address go to you in writing.
Engineering and your test
We copy the board, recover the schematic or read out the chip, then send samples. The balance is due after your own test passes.
Files, and production if wanted
Full file package delivered. SMT assembly, X-ray BGA inspection and flying probe testing are in house if you need boards built.
Where the risk sits
If we cannot do it, you pay nothing
Sending a board to a supplier on the other side of the world is a real risk. These five terms move most of it onto us, and they are in the quote you receive, not only on this page.
Feasibility assessed free, before you commit
50% deposit, balance only after your test passes
Full refund if the sample boards or chips fail your test
NDA signed before anything ships
Your files are never reused, resold or shown
Recent work
Three boards, three reasons the original files were gone
6-layer industrial control board, immersion gold
Layers6
Parts480
Lead time11 days
The MCU vendor had gone out of business and the plant had two spare boards left. Firmware extracted, board cloned, line back in production.
Blind and buried vias, laser microvia HDI, RF and microstrip, ceramic substrate, high component density, EMC-critical telecom boards, 1 to 32 layers.
In-house SMT lines, X-ray BGA inspection and flying probe testing mean the file you receive has already been proven on a physical board, not only on screen.
Minimum trace / space3 mil
Via typesThrough, blind, buried
SubstratesFR-4, Rogers, ceramic, flex
InspectionX-ray BGA, AOI, flying probe
Package types read outDIP, SOP, QFP, QFN, BGA
Before you send an enquiry
Five questions we answer every day
Gerber files ready for any fab, a BOM with real manufacturer part numbers, placement data, the PCB source file, and a prototype we have already built and tested against your sample. Boards from 1 to 32 layers, starting at $150.
A copy reproduces the board exactly as it is and is faster and cheaper. Reverse engineering recovers the schematic so you can change something, which is what you need when a part has gone obsolete. Tell us the goal and we will say which one actually fits.
Our unlock database covers 5000+ models, and 126 of them across 28 families are published on the chip list page. If yours is not listed it usually still works, we just have not published it. Send the marking and the check is free.
You pay nothing. The feasibility check costs nothing and any deposit is returned in full. We say so early rather than late.
We sign an NDA before you ship. Files are returned or deleted on request after delivery, and nothing goes into a portfolio without written permission.
Two photos of the board, or a chip marking, is enough to start. You get feasibility, lead time and price back within 24 hours, with no obligation to go further.
