PCB Copy Service
Turn a finished board back into manufacturing files. We copy PCBs and PCBAs 1:1 — recovering Gerbers, schematic and BOM so you can rebuild a design with no original files.
REV.A · 1:1 CLONE · pcbcopyservice.com
A PCB Copy Service reverse-engineers a physical circuit board to recreate everything a factory needs to make it again — copper layout, drill data, solder mask, silkscreen and the full parts list. It is how engineers recover lost design files, replace obsolete hardware, and put a working board back into production.
What does a PCB Copy Service actually do?
Two jobs sit under the same name. Knowing which one you need is the first step to an accurate quote — and it changes the price more than anything else.
PCB Copy
Duplicates the empty printed circuit board. The goal is a set of production files that match the original copper exactly.
- Recover Gerber & drill (NC) files
- Match layer stack-up, track width and spacing
- Reproduce solder mask & silkscreen
- Optional rebuilt schematic for future edits
PCBA Copy
Duplicates the board and everything on it, so you receive working, populated boards rather than blanks.
- Identify every component & build the BOM
- Match footprints, values and polarity
- Reproduce assembly & soldering
- Functional test on finished boards
How to copy a PCB
This is the route a professional board clone follows from a single physical sample to files a factory can build. Multilayer and assembled boards add steps, but the spine is always the same.
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01
Document the sample Intake
Photograph both sides, measure outline and thickness, count the layers, and log every visible part. Good documentation prevents mistakes downstream and defines the scope of the copy.
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02
Scan every layer Imaging
High-resolution scans or photos capture the copper pattern, pads, vias and drill positions. Outer layers first; the cleaner the image, the more accurate the trace work.
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03
Separate the inner layers Multilayer
For 4-layer boards and up, the laminate is carefully ground or delaminated so each buried copper layer can be imaged on its own. This is the step that makes multilayer copies slower and costlier.
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04
Trace the nets Digitise
Each scan is converted to vector copper and the connections between pads are followed layer by layer, rebuilding the board's electrical map (the netlist) — the backbone of an accurate copy.
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05
Rebuild layout & Gerbers CAD
Copper, drill, solder mask and silkscreen are recreated in PCB CAD and exported as production-ready Gerber and NC drill files, matched to the original stack-up.
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06
Extract the BOM Parts
Every component is identified — value, footprint, polarity and reference designator — and listed in a bill of materials. Worn or unmarked parts are measured or cross-referenced to a likely match.
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07
Prototype & verify Test
A sample board is fabricated and electrically compared with the original. Any mismatch is corrected before sign-off so the deliverable is a true 1:1 copy, not just a close one.
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08
Release for production Build
Verified Gerbers, drill data and BOM are packaged so you can manufacture the board at any quantity — from a handful of repairs to a full production run.
One honest caveat about firmware
Copying the copper and the parts is one thing; the code inside a microcontroller is another. Programmed firmware is usually read-protected and protected by copyright — a PCB copy reproduces the hardware, not the software locked inside it.
How to copy a PCBA
A PCBA copy starts with the same PCB copy above, then adds the work of reproducing every part and the assembly itself — so you receive populated, testable boards.
Copy the bare board
Run the full eight-step PCB copy first to recover an exact board to build on.
Identify components
Read markings, measure values and decode packages to pin down every part on the board.
Build & source the BOM
Compile the bill of materials and find current, in-stock equivalents for anything obsolete.
Assemble & test
Fabricate, place and solder the parts, then functionally test the finished assembly.
PCB copy cost — what you're really paying for
There's no single price for a board copy. Cost tracks complexity: the more layers, the smaller the parts and the more deliverables you want, the more engineering time it takes.
| Service | Typical range | Lead time |
|---|---|---|
| 1–2 layer PCB copy (Gerbers) | $50 – $150 | 1–3 days |
| 4-layer PCB copy | $150 – $400 | 3–5 days |
| 6–8 layer PCB copy | $400 – $1,200 | 5–10 days |
| 10+ layer / HDI / dense BGA | from $1,200 | quote |
| Schematic reverse engineering | +$100 – $1,000 | +2–7 days |
| BOM extraction | $50 – $300 | 1–3 days |
| PCBA copy (board + assembly) | from $200 +parts | quote |
Ranges are illustrative industry estimates to set expectations, not a quote. Your exact price depends on the specific board — send your details for a firm figure.
Why send it to specialists instead of guessing
A board copy is only useful if it's accurate. Reverse engineering rewards experience, the right equipment, and a verification step most DIY attempts skip.
Accuracy that's tested
Every clone is electrically verified against the original, so you build from files that actually work — not a best guess at the copper.
Confidentiality
Your board and your files stay private. An NDA is available on request before anything is shared.
Obsolete-part sourcing
End-of-life components are found, cross-referenced or redesigned around — keeping a board buildable long after the original parts disappear.
PCB copy questions, answered
Q1 Is copying a PCB legal?
Reverse engineering for repair, maintenance, replacing obsolete equipment or recovering your own lost design files is common and legitimate. You're responsible for holding the rights to copy a design — duplicating a board protected by someone else's patents, copyright or trade secrets without permission can infringe their intellectual property. When in doubt, get legal advice for your specific case.
Q2 Do I need the original schematic or design files?
No. The whole point of a copy service is that it works from the physical board. The schematic and netlist are reconstructed during the process — you only need to ask for the schematic if you want it as a deliverable for future changes.
Q3 Can you copy multilayer and BGA boards?
Yes. Multilayer boards are handled by separating and imaging each inner layer; BGAs and fine-pitch packages are identified and their footprints rebuilt. These boards simply take more time and care, which is reflected in the cost.
Q4 Will the copied board work exactly like the original?
The hardware is reproduced 1:1 and verified by test, so a bare-board or assembled copy behaves like the original. The exception is programmed firmware inside protected microcontrollers — that software is copyrighted and usually read-locked, so a hardware copy doesn't include it.
Q5 What files do I receive at the end?
Typically production-ready Gerber files and NC drill data, plus a bill of materials. A rebuilt schematic, editable CAD source and assembly drawings can be added on request. For a PCBA copy you can also receive finished, tested boards.
Q6 How do I send my board or files?
Start with the enquiry form below or our PCB clone page. Share clear photos, the layer count and what you need (board only, schematic, BOM, or full PCBA). You'll get back a scope, price and turnaround, and shipping instructions for the physical sample.
Send your board.
Get a copy.
Tell us about your board and what you need. You'll receive a clear scope, an exact price and a turnaround — with no obligation to proceed.
- Free, no-commitment quote
- NDA available before you share anything
- Works for PCB or full PCBA copies
Enquiries are handled by our engineering partner. For a professional PCB Copy Service, your details go straight to the PCBSync PCB clone team.
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