PCB Copy &
Cloning Services
Rebuild the files.
Reproduce the board.
Turn your physical PCB into an agreed package of Gerber, drill, BOM and assembly data. Define the sample handling, optional firmware work and prototype verification needed for a dependable replacement.
What does a PCB copy service recover?
PCB copy recovers the design and manufacturing information needed to reproduce an existing circuit board from a physical sample. PCB cloning is a commonly used name for the same objective. The useful result is a defined file package and an agreed way to verify the replacement.
The work begins with the board you have: its copper connections, outline, holes, component placements and construction. Engineers reconstruct those details in a design environment and prepare information that a manufacturer can use. A board photograph alone is not a manufacturing package, and copying its visible traces does not establish hidden-layer connections or component values.
Customers typically need this service when original Gerber files are lost, a supplier has stopped supporting a product, or a maintenance team needs a repeatable source of spares. The initial review should establish whether your aim is an electrically equivalent replacement, a documented design, or a changed product. That distinction determines the work, deliverables and tests.
If you need to understand or modify the circuit, include PCB reverse engineering and schematic recovery. If the board depends on unavailable program data, include an IC unlock and firmware assessment. These requirements are related, but they are not automatically included in a PCB layout recovery quote.
Preview the PCB copy file package.
Open a file group to see what to request and how to review it. This is an illustrative example, not a customer project or a ready-to-manufacture design. Your written scope defines the actual files and checks.
01 Schematic & connectivity
design/schematic.pdf + agreed editable sourceconnectivity/netlist.csv + verification notes
A readable schematic explains the circuit. A netlist records connections. The following row illustrates how an unresolved connection can be recorded without presenting it as verified.
| Endpoint A | Endpoint B | Status | Next check |
|---|---|---|---|
| J1, pin 1 | F1, pin 1 | To verify | Compare with physical continuity evidence |
02 Fabrication & assembly
fabrication/gerber/ + drill files + stackup notesassembly/placement.csv + assembly drawings
Review the board outline, layer order, hole sizes and units with the fabricator. Assembly information should identify the reference designator, side, rotation and position. A photo overlay does not supply hidden copper or confirm material and impedance requirements.
Understand Gerber recovery and its limits →03 BOM & unresolved parts
components/bom.csv + identification notes
Useful columns include reference designator, quantity, value, package, manufacturer part number, identification evidence and unresolved questions. Separate an identified original from a proposed substitute; neither a similar marking nor a matching footprint establishes compatibility.
See what belongs in a recovered BOM →04 Revision & acceptance records
release/file-manifest.csvverification/review-notes.pdf + agreed test records
The manifest ties the delivered files to one revision. Acceptance records state what was checked, the reference used and any open items. A prototype functional test, firmware recovery and product qualification each need their own agreed scope.
Review the verification scope →Editable planning template · No customer data · No upload or signup
Describe your board. Prepare a useful enquiry.
Choose what you know, review the suggested questions and create an editable project brief. This tool organizes the information for engineering review; it does not issue an automatic quote or guarantee feasibility.
PCB manufacturing file recovery
Deliverables to discuss
Next useful step
Inputs and checks to confirm
View or edit your PCB copy brief
Changing a selection rebuilds the summary. Keep additional notes in the enquiry form.The planner runs in this browser. Your brief is sent only when you submit the enquiry.
A PCB copy package your manufacturer can use.
Specify the deliverables and software versions in the quote. Fabrication data, assembly information and editable source files serve different purposes; asking for a “copy” alone does not define the complete handover.
Gerber, drill and board information
Copper, solder mask, silkscreen, outline and drill data describe the bare board. The package should also define the relevant stackup, material and fabrication notes. Special requirements such as controlled impedance need an agreed specification rather than assumptions based on appearance.
BOM with identification notes
A bill of materials links reference designators to component descriptions and identified part numbers. Unknown markings, unavailable parts and proposed substitutes should be visible in the documentation. A similar package is not enough to establish an electrically suitable replacement.
Placement data and assembly drawings
Centroid or pick-and-place coordinates, component orientation and assembly notes help a factory populate the recovered layout. Connector orientation, polarity and mechanical fit deserve particular attention when the replacement must work with existing harnesses and an existing enclosure.
Editable design files and agreed extras
Confirm the native EDA format your team can open and maintain. A readable schematic, firmware files, programmed chips and assembled prototypes can be added to the scope. The delivery checklist should identify each item and its associated verification evidence.
One project, a defined boundary. Gerber files describe board fabrication; they do not contain the full BOM, original firmware or a readable circuit schematic. Confirm each required output explicitly.
Can PCB copy start from photos or traced files?
Clear photos and trace annotations can speed up the first conversation. Include orientation, a scale reference, readable component markings and any known damaged areas. They help describe the board, but do not establish every connection, the stackup, component identity or manufacturing tolerance.
If you have a netlist, schematic or editable PCB project, tell us which parts were checked against the hardware. Keep unresolved connections and proposed substitutions visible. A complete, usable fabrication package may mean you need file review or production preparation rather than full PCB reconstruction; establish what is missing before commissioning recovery.
Confirm the source application, version and desired handover format. A schematic export is not automatically a validated PCB layout, and a Gerber viewer cannot supply the missing firmware or a complete BOM.
Choose tools by their inputs and outputs →From sample intake to a checked handover.
The recovery method follows the construction and condition of your board. These stages establish the scope and evidence, rather than promising the same treatment for every sample.
Evaluate the sample and required result
Share photographs, dimensions, operating context and the files or replacement boards you need. We review missing components, damage, likely layer construction and firmware dependencies. Your quote identifies the accepted work and any unresolved questions.
Document the board and handling plan
Record the reference board, mechanical features, component positions and known modifications. Agree which samples may be dismantled and whether a working reference must remain intact. Internal-layer recovery can require invasive work, so this decision precedes analysis.
Reconstruct layout and component data
Recover connections and geometry, build the layout and identify the BOM. Multilayer construction, vias, fine-pitch packages and unusual substrates affect the method. Any proposed substitute or uncertain detail is reviewed as part of the engineering scope.
Check files and build the agreed prototype
Review connectivity, manufacturing data, mechanical fit and component information. Where prototype assembly is included, define the parts, firmware and test conditions needed to compare its behavior with the reference. Resolve discrepancies before acceptance.
Release the agreed files and records
Deliver the named file formats and verification information after the agreed acceptance step. Record the delivered revision so future fabrication and assembly use a consistent package. Follow-on production requirements can then be reviewed against that baseline.
Verification connects the files to your equipment.
A visually similar board is not enough. Agree what will be measured, what the replacement must do and who will provide the test setup.
Design and manufacturing checks
Review recovered connectivity, copper geometry, drill features, board outline, component data and assembly orientation. Document differences from the sample, including substitutions and repaired damage. For special constructions, include the relevant stackup and impedance checks in the scope.
Prototype and functional checks
Define the supply conditions, loads, interfaces, firmware and operating modes used for comparison. Your equipment or fixture may be needed to validate a replacement properly. The acceptance record should state which functions were tested and identify any limits to the available reference.
A working prototype does not automatically establish regulatory approval or suitability for a new operating environment. If your replacement needs additional qualification, define that requirement at the start.
Sample condition changes the recovery plan.
Before you send your enquiry
0 of 5 details prepared
One working board
Tell us immediately if the sample is the last working unit in service. The appropriate plan may differ from a project with several expendable boards. Agree permitted disassembly, sample-return condition and how a functional reference will be retained before shipping.
Multilayer, HDI, RF and flex construction
Inner copper, blind or buried vias, materials and mechanical behavior cannot be inferred reliably from the top and bottom photographs. PCB-Copy reviews boards across a 1–32 layer range, but the precise construction still determines feasibility and the recovery approach. High-frequency and flexible designs need requirements beyond a trace image.
Damaged or incomplete boards
Localized damage may leave enough surrounding information for recovery. Missing routing across several layers, erased firmware or unidentified components can limit the result. Send a clear description of previous repairs, burnt areas and missing parts. A second board, partial files or equipment documentation can materially improve the review.
Authorization and confidentiality
We work on boards you own or are authorized to reproduce. Ask Judy to arrange an NDA before sending confidential information, and follow the legitimate-use policy. Ownership of a physical sample alone should not be treated as confirmation of every reproduction right.
Recover the board and the program it depends on.
A German packaging plant had only two spare controller boards remaining after support for the original MCU ended. The project combined firmware recovery, six-layer PCB copy and prototype testing on the actual machine before file release.
- Board
- 6 layers
- Components
- 480
- Project time
- 11 working days
The customer gained a repeatable route to locally produced spare boards. This example illustrates why a PCB copy scope needs to account for both hardware and firmware when the replacement relies on a programmed controller.
Read the full projectBudget for engineering, then for production.
Written quote after sample review
PCB copy is an engineering task. Its price should not be confused with the price per bare board at a fabrication factory. Layer count, board area, component density, special construction and the condition of your sample all affect the recovery effort. The number of boards you eventually manufacture is a separate production decision.
Published starting prices provide an initial reference: 1–2 layer work starts at $150, 4–6 layers at $280 and 8–10 layers at $550. Complex HDI, RF and higher-layer work requires its own review. Confirm whether schematic recovery, firmware, component sourcing, prototype assembly and testing are included before comparing totals.
Indicative timing begins at 3–5 working days for selected 1–2 layer projects, with longer schedules for multilayer recovery and combined work. Sample availability, component procurement and access to the equipment test setup can affect the overall schedule. Your written quote defines the actual milestones.
The initial feasibility review is free. Our terms are a 50% deposit, the balance after your test passes and a full refund if the agreed sample boards or chips fail your test. Define the scope, accepted samples and test conditions in writing before the order begins.
Useful PCB copy guides.
Explore a specific requirement before you prepare your sample or compare project scopes.
Make the next project decision with confidence.
PCB Repair vs Replacement: A Guide for Legacy Equipment
A failed circuit board creates two decisions: how to restore the machine now, and how to support it when the next board fails. Compare the options before committing to a repair or a replacement project.
BIN vs HEX Firmware Files: What Your Replacement MCU Needs
A firmware file is only useful when the destination, memory map and programming requirements are understood. Learn what BIN and Intel HEX describe, and what else a replacement microcontroller may need.
PCB Clone Not Working? Check Hardware, Firmware and Test Conditions
A board that looks identical can behave differently. Organize the evidence before changing parts or rewriting firmware, so the next engineering step addresses the actual mismatch.
PCB copy: your questions answered.
What is a PCB copy service?
A PCB copy service recovers manufacturing information from a physical circuit board when the original design files are unavailable. The agreed package may include PCB layout data, Gerber and drill files, a bill of materials and assembly information. Schematic recovery, firmware recovery and assembled prototypes are distinct deliverables that should be included explicitly in the quote.
Is PCB copy the same as PCB cloning?
PCB copy and PCB cloning are often used for the same objective: reproducing an existing board from a sample. The terms do not establish which files, components, firmware or tests are included. Define whether you need bare-board fabrication data, editable design files, an assembled replacement, or all three before comparing quotes.
Can you copy a PCB without Gerber files or a schematic?
Yes, recovering missing design information is the purpose of this service. A physical sample is normally required to establish and verify copper connections, drilled features and component details. Photographs help the initial review but do not reliably expose hidden layers or all component values. Missing or damaged information may require another sample or supporting documentation.
How many sample boards are required?
One working board can start the evaluation. Two samples are preferable when one can be kept as a reference while the other is used for disassembly or internal-layer analysis. The final requirement depends on construction and the permitted recovery method. If your board is the only working unit, say so before shipping and agree which work is allowed.
Will my original board be damaged?
Component removal, layer exposure or other invasive analysis can damage a sample or make it unusable. The handling plan is agreed before work begins, including whether a reference must remain intact and what condition to expect on return. Do not assume a multilayer PCB copy is nondestructive simply because the board can be photographed.
Does a copied PCB include the firmware?
A recovered PCB layout does not automatically recover the program inside a microcontroller or programmable device. If the replacement needs firmware, provide chip markings and tell us whether working program files are available. IC unlock and programmed-sample testing can be reviewed as separate parts of the project. Device settings, external memory and calibration may also matter.
How much does PCB copy cost and how long does it take?
Published PCB copy starting prices begin at $150 for selected 1–2 layer work. These are engineering starting points, not prices per manufactured board. Layer construction, size, component density, required files and prototype testing affect the written quote. Indicative 1–2 layer timing is 3–5 working days; multilayer and combined projects need a confirmed schedule.
How do you verify that the copy works?
Verification is defined around the intended replacement. It can include layout and connectivity checks, BOM review, manufacturing-data checks, prototype assembly and functional comparison with the reference in an agreed test setup. Passing a file check alone does not prove equipment-level performance. Supply operating conditions, fixtures and acceptance criteria early, especially where firmware or high-frequency behavior matters.
Start your PCB copy project.
Send clear board photos, the sample condition and your required outcome. Judy will coordinate your free initial review. Need an NDA? Contact us before sharing confidential information.
Your contact: Judy
Judy@4PCBA.com
Bao'An Shenzhen China