Inverter PCB Copy | NDA-Protected Reverse Engineering

What Is Inverter PCB Copy?

Inverter PCB copy is the process of reverse-engineering an existing inverter circuit board to extract production-ready Gerber files, a verified bill of materials, and — when needed — a full schematic. The service covers every inverter topology: single-phase string inverters, three-phase central units, micro-inverters, UPS modules, VFD control boards, and welding-supply power stages. Our engineers work from your physical sample under a signed NDA, delivering files accurate to ±0.5 mil (0.0127 mm) trace/space so you can reorder or modify the design without the original OEM’s cooperation.

Why Inverter Boards Are Harder to Copy Than Typical PCBs

Inverter PCBs combine high-voltage power paths, sensitive analog feedback loops, and fast-switching gate-driver signals on one substrate. That mix creates reverse-engineering challenges most commodity boards never present.

Thick-Copper and Mixed-Weight Stackups

Power-stage layers often use 2 oz or 3 oz copper for bus bars carrying 20–60 A, while the control section sits on standard 1 oz foil. Cross-sectioning must identify each layer’s weight individually; guessing wrong shifts current capacity by 30–40 % and changes thermal behavior.

Creepage and Clearance Constraints

DC bus voltages of 400–800 V demand strict creepage distances — typically ≥ 6.4 mm on FR-4 per IPC-2221B for 800 V working voltage. During Gerber extraction we measure every high-voltage gap and flag any that fall below the standard, because a clone that shrinks a clearance is a fire risk.

Thermal Management Structures

Many inverter boards use heavy copper pours, thermal vias under MOSFET/IGBT pads, or aluminum-core substrates for heatsinking. These features must be captured in the drill file and copper-pour definitions exactly, not approximated.

Impedance-Sensitive Gate-Drive Traces

Gate-driver loops on SiC or GaN inverters are routed as impedance-controlled pairs (typically 50 Ω single-ended or 100 Ω differential) with trace widths as narrow as 4 mil. Our impedance-controlled copy and stackup recovery process uses TDR verification to confirm characteristic impedance within ±10 % of the original.

Inverter Types We Routinely Copy

If your inverter board uses HDI construction with microvias — common on newer micro-inverters — we add sequential-lamination analysis to the scope.

How the Inverter PCB Copy Process Works

Step 1 — Sample Intake and NDA

Ship one working or non-working board. We sign a mutual NDA before any inspection begins. Boards arrive via DHL/FedEx; we photograph and catalog every component on receipt.

Step 2 — Delayering and Scanning

Each copper layer is imaged at 2400 DPI minimum. For boards with 3 oz or heavier copper, we adjust etch-back timing to avoid over-etching fine control traces on the same layer. Inner-layer registration targets are captured to maintain ±2 mil alignment.

Step 3 — Gerber Reconstruction

Layer images are vectorized into Gerber RS-274X. Power planes get flood-fill verification against the original; signal traces are checked for width consistency. Drill files are generated in Excellon format with plated and non-plated holes separated.

Step 4 — BOM Extraction

Every component is identified by package, value, and manufacturer part number. For inverter boards this means matching exact IGBT/MOSFET modules (e.g., Infineon FF150R12RT4, ON Semi NGTB40N120FL2), gate-driver ICs, current-sense resistors (±1 % tolerance shunts), and bulk capacitors. We cross-reference live distributor databases so your BOM is orderable on day one.

Step 5 — Schematic Recovery (Optional)

Netlist extraction from the Gerber set feeds into schematic capture. Power-stage topology, feedback loops, and protection circuits are drawn in hierarchical sheets — typically in Altium or KiCad format. This step adds 3–5 working days but is essential if you plan design modifications.

Step 6 — Review Package Delivery

You receive Gerber (RS-274X), drill (Excellon), BOM (Excel + CSV), centroid/pick-and-place file, and — if ordered — schematic plus source project files. A comparison overlay report shows original-vs-clone alignment.

What Gets Delivered

Pricing Signals and Lead Time

Inverter PCB copy pricing depends on layer count, board area, and copper weight. Rough ranges for orientation:

• 2-layer inverter board (≤ 200 × 150 mm): starting around $350–$600, 7 working days. For simpler 2-layer board copies, turnaround can be even faster.
• 4-layer mixed-copper board: $600–$1,200, 8–12 working days.
• 6-layer central-inverter board (large format): $1,200–$2,500, 10–15 working days.
• Schematic recovery add-on: +30–50 % of base cost, +3–5 days.

These are starting points. Conformal coating removal, potting compound extraction, or BGA reballing for component ID can add cost. We provide a fixed quote after a free visual evaluation of your sample — no surprises mid-project.

Common Failure Modes We Catch

Inverter boards fail in predictable patterns. Understanding these helps you decide what to copy and what to improve in the clone:

• Gate-driver via fatigue: Thermal cycling cracks vias under driver ICs. We flag via sizes below 0.3 mm finished hole and recommend filled/capped alternatives in the clone.
• Electrolytic capacitor drift: DC-link caps rated 105 °C / 2,000 h degrade after 3–5 years in hot enclosures. The BOM notes equivalent long-life replacements.
• Solder-joint cracking on IGBT modules: Heavy components on thick-copper pads experience CTE mismatch. We document pad geometry so your assembler can apply the correct solder-paste stencil thickness (typically 150–200 µm for these pads).
• Creepage erosion from dust/moisture: If the original board shows tracking marks, we note the affected clearances and recommend conformal coating zones in the clone.

Who Needs Inverter PCB Copy?

Legacy Equipment Owners

When the OEM discontinues a UPS or VFD control board and lead times for spares stretch past 6 months, a copy lets you manufacture replacements in-house or through a contract assembler. This is especially common for welding machine power boards and industrial VFDs from the early 2010s.

Solar O&M Companies

String inverters deployed 8–12 years ago are now failing outside warranty. A copied board plus a small production run of 50–200 units can extend plant life by another decade at a fraction of full inverter replacement cost.

Product Engineers Doing Competitive Analysis

Extracting a competitor’s topology, component choices, and thermal strategy is standard practice in power-electronics R&D. The schematic recovery add-on makes this analysis structured rather than ad hoc.

Contract Manufacturers Replacing Obsolete Subassemblies

If you build consumer electronics or appliance products that embed an inverter sub-board, and that sub-board’s supplier has disappeared, a copy restores your supply chain.

Confidentiality and IP Protection

Every inverter PCB copy project starts with a signed mutual NDA. Sample boards are stored in a locked intake area, files are kept on air-gapped workstations during the project, and all data is purged 90 days after delivery unless you request archival. We do not resell, redistribute, or reuse any extracted design data.

Related Board-Copy Services

• Laser equipment power-supply board cloning — similar high-voltage, thick-copper challenges.
• Full reverse engineering service overview — see all board types and industries we support.

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