PCB reverse engineering: from an old board back to a complete data package
When the original manufacturer is gone and the documentation is lost, the board itself is often the only source of truth. We measure it, recapture it and turn it into manufacturing data that any modern PCB fabricator and assembler can work with.
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What PCB reverse engineering means
PCB reverse engineering is the process of reconstructing the design data of an existing printed circuit board: outline, holes, copper layers, components and the electrical connections between them. The result is a set of files that allows the board to be manufactured again – without the original CAD project.
It is not about copying someone else's product. Our customers are operators and maintenance teams who own the equipment, need spare parts and can no longer buy them. Before we start, you confirm that you hold the rights to the design or that rebuilding it for repair and replacement is permitted.
What you can send us
| Input | What we do with it |
|---|---|
| Physical board (bare or assembled) | Measure outline and holes, photograph and scan both sides, trace the copper, identify components |
| Second board that may be destroyed | Remove components and, for multilayer boards, look at inner layers |
| Parts list (BOM) | Cross-check against the board, add manufacturer part numbers and alternatives |
| Gerber files, films or paper plots | Convert or recapture them, check against the physical board |
| Schematic or old drawings | Use them as reference and correct them where the board differs |
| Photos and measurements only | First assessment; for the final data we usually need the board itself |
Incomplete is normal. Most requests arrive with a board and a partial parts list. Tell us what you have and we will tell you what is missing.
How we work
- Free assessment of your documents and photos: feasibility, level of effort, open questions.
- Fixed-price offer for the data package. Work only starts after your order.
- Capture: outline and drilling by measurement, copper by high-resolution scans of both sides, components by marking, measurement and datasheets.
- Rebuild schematic and layout in KiCad, so you receive an editable project and are not locked into an expensive licence.
- Cross-check: netlist against the physical board, footprints against datasheets, outline against the sample.
- Delivery of the complete package with a review report that lists every assumption and open point.
What you receive
- Gerber files (RS-274X) and Excellon drill data
- Bill of materials with manufacturer part numbers and approved alternatives
- Pick-and-place (centroid) data for automated assembly
- Fabrication drawing with stack-up, material, finish and tolerances
- Assembly drawing with polarity and reference designators
- Schematic as PDF and the editable KiCad project
- Review report with assumptions, risks and points you need to confirm
Limits – what reverse engineering cannot do
A board can be measured, but some things are not visible on it. We tell you about these before you pay anything:
- Read-protected firmware in microcontrollers or PLDs cannot be recovered. If you have the firmware file or the rights to it, we include it.
- Custom chips (ASICs) without a replacement usually mean a redesign rather than a rebuild.
- Inner layers of multilayer boards need X-ray or destructive analysis. We start with 1–2 layer boards and handle multilayer on request with a specialised partner.
- Original design intent – for example why a certain trace width was chosen – can only be inferred. We document such assumptions.
Typical applications
Control boards in machines that have to run for another twenty years, ground support and test equipment in aviation, interface boards in rail and infrastructure, and electronics in classic cars and vintage equipment. For boards installed in certified aircraft, the data package supports – but does not replace – the approval by a design organisation.
Questions
How much does PCB reverse engineering cost?
It depends on layer count, number of components and what documentation exists. The assessment is free; you then receive a fixed price for the data package before any work starts.
How long does it take?
The assessment takes a few working days. A simple single- or double-sided board is typically done within a few weeks; the offer states the exact delivery time.
Do I have to send the original board?
For the final data, yes – a physical sample gives the best accuracy. Ideally you send two: one stays intact, one may be taken apart. We give you the shipping address after the first contact.
Can you also manufacture the boards?
Yes, through qualified partner fabricators and assemblers. You can also use the data package with your own supplier.