Single Layer PCBs: A Comprehensive Guide to Design, Manufacturing, and Applications

Introduction

Printed circuit board (PCB) basics start with the single-layer PCB—also called a single-sided or 1-layer board—featuring one copper layer on an insulating substrate. prized for simplicity, fast turnaround, and low cost, these boards remain common in consumer electronics, industrial control, and simple power modules even as multilayer designs grow. This guide explains what single-layer PCBs are, their stack-up, key design rules and DFM, manufacturing steps and finishes, cost drivers, and typical applications—so you know when a 1-layer board is the right fit and how to build it correctly.

What is a Single Layer PCB?

Single Layer PCB ( also called Single sided PCB or 1 layer PCB) is named for its single layer of conductive patterns. While multilayer PCB technology is increasingly popular, single layer PCBs remain widely used due to their unique advantages. They are not only structurally simple and cost-effective but also extremely reliable in specific fields. Below, we will delve into 1 layer PCBs, covering their basic structure, design and manufacturing processes, common applications, and future development trends.

Basic Knowledge of Single Layer PCBs

1 layer PCBs are not as complex as they might seem; their biggest feature is their simple structure. They mainly consist of the following layers:

• Substrate: This forms the "skeleton" of the PCB, responsible for support and insulation. The most commonly used material is FR-4, known for its good performance and widespread use. The choice of substrate directly affects the electrical performance, support strength, and cost of the circuit board.
• Conductive Layer: Simply put, this is a layer of copper. Through special processes, the copper is etched into the required circuit pattern, allowing current to flow properly. The thickness of the copper foil (like 1oz, 2oz) will affect the current-carrying capacity and impedance of the circuit.
• Solder Mask: This is a layer of insulating ink covering the conductive layer, usually green due to its high usage frequency and relatively low cost. Other colors, such as red, purple, and black, are also available. It acts like a protective film, preventing short circuits during soldering and protecting the circuit from oxidation.
• Silkscreen: This is the white text printed on the outermost layer, used to mark the positions and information of components, facilitating assembly, testing, and maintenance.

Compared to multilayer PCBs, single-sided ones have distinct advantages: low cost, quick design and manufacturing, and decent heat dissipation. However, they also have drawbacks; with only one layer of routing space, they cannot accommodate very complex circuits and may face challenges in signal transmission and interference resistance.

Design Considerations for Single Layer PCBs

Despite their simple structure, the design of single sided PCBs requires careful consideration to ensure circuit performance and manufacturability.

Schematic Design

This is the starting point for all PCB designs. The most important aspect is selecting the right components and ensuring they have corresponding package libraries in the design software. Power and ground lines are the "lifelines" of the circuit; on a single layer board, we usually create a ground plane by using a large area of copper, which effectively lowers resistance and reduces noise. Critical signal lines should be kept short and away from interference sources, and filtering may be necessary.

PCB Layout

This part poses the biggest challenge in single-sided design and must follow several core principles:

• Component Placement: Group functionally related components together to shorten traces. Also, consider thermal management by placing heat-generating components in well-ventilated areas to avoid heat concentration.
• Routing Strategy:

    ○Trace Width and Spacing: Trace widths should be determined based on current size to ensure they can handle adequate current. Sufficient spacing should be left between traces to prevent short circuits.
    ○ Corner Treatment: When routing turns, it's best to use 45-degree angles or arcs instead of right angles, as right angles can cause signal reflections.
    ○ Power and Ground Lines: In addition to copper pour, star grounding can be used to prevent ground loops and noise generation.

• EMC (Electromagnetic Compatibility): This is a challenging aspect of single-sided design. Large current loops should be avoided during design, and decoupling capacitors should be placed at power entry points to filter out high-frequency noise and reduce electromagnetic interference.
• DFM (Design for Manufacturability): Manufacturing process limitations, such as minimum hole diameter, minimum pad spacing, and window size, should be considered during the design phase. Meeting these requirements helps lower pcb manufacturing costs and improve yield rates.

Design Software Selection

There are various PCB design software available, such as Altium Designer, Eagle, and KiCad. Choose the one you are most comfortable with and accustomed to.

Single Layer PCB Manufacturing Process

While the single layer PCB manufacturing process is simple, each step must be strictly controlled to ensure final quality.
Manufacturing Process

• 1. Pre-treatment: Clean the substrate's surface to remove oil and dust, ensuring good adhesion for subsequent processes.
• 2. Exposure and Development: Transfer the designed circuit pattern onto the copper foil using photolithography.
• 3. Etching: Use chemicals to remove copper that is not protected by the "pattern," forming the required circuit. This is the most critical step.
• 4. Drilling: Use a drill to create holes for component leads and mounting holes according to the design drawings.
• 5. Printing Solder Mask and Silkscreen: First, cover the circuit with a protective film (usually green), then print component markings and text information for easy identification.
• 6. Surface Treatment: This step protects exposed pads from oxidation and facilitates soldering. Common surface treatment processes include:

    ○ HASL: Cost-effective but may not provide a very flat surface.
    ○ ENIG: Provides a very flat surface, suitable for components requiring fine soldering.
    ○ OSP: Eco-friendly and lower cost, but has a relatively shorter shelf life.

• 7. Testing and Quality Control: Finally, use methods like flying probe testing or AOI ( Automated Optical Inspection) to check for short circuits, open circuits, and ensure each board meets quality standards.

Single Layer PCBs Cost

How much does a single PCB cost? Single layer PCBs cost usually range from $0.1 to $5 for quick-turn with Fr-4 material. To understand the 1 layer PCB price, we can mainly analyze it from two core factors: PCB materials and PCB processing technology. These two factors together determine its low price.
The first is the material cost. Single layer PCBs only cover copper foil on one side of the substrate, while double-layer or multi-layer boards need to be stacked between multiple layers. This single-sided structure greatly reduces the demand for key raw materials such as copper foil and insulating materials, fundamentally reducing material costs.
The second is the processing cost. The production process of single sided PCB is relatively simple. Since only one side needs to be wired and etched, the factory does not need to deal with complex inter-layer alignment, multi-layer lamination or buried vias. The simple process not only improves production efficiency, but also reduces the error rate, thereby reducing labor and equipment costs.
Therefore, the low-cost advantage of 1 layer PCB mainly comes from its streamlined material usage and simplified manufacturing process.

Want to know all the factors that affect PCB Cost? Click to view the in-depth analysis article: "Custom PCB and PCBA Cost Analysis: How to Optimize Design and Reduce Expenses".

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The final price is determined by your Gerber files.

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Typical Applications of Single Layer PCBs

Thanks to their low cost and quick manufacturing, single layer PCBs have become the preferred choice for many simple electronic products.

• Consumer Electronics: Simple control boards for various remote controls, LED lights, rice cookers, or fans are classic applications of single layer PCBs.
• Industrial Control: Often used in low-cost sensors or simple relay control boards.
• Power Modules: Such as mobile phone chargers, which do not have high routing requirements.
• Medical Devices: Some relatively uncomplicated portable medical sensors or diagnostic tools.
• Education and DIY Projects: For beginner electronics enthusiasts, single layer PCBs are an ideal choice for learning electronic design and circuit making, as they are simple and user-friendly.

Future Development and Trends of Single Layer PCBs

Despite facing competition from multilayer boards, single layer PCBs continue to evolve, with numerous future opportunities.

• Material Innovation: The emergence of new materials, such as more environmentally friendly and durable substrates, even flexible substrates, will further expand the application boundaries of single layer PCBs.
• Manufacturing Process Enhancements: With the proliferation of automation and finer etching technologies, production efficiency and precision for single-sided boards will continue to improve, enabling smaller trace widths and spacings.
• IoT: A large number of IoT devices that are sensitive to cost and size present a significant market demand for single layer PCBs, becoming a new growth point.
• Intelligent Production: The introduction of big data and artificial intelligence technologies will optimize production processes, significantly improving yield rates and production efficiency.

Conclusion

In summary, single layer PCBs hold an irreplaceable position in the electronics industry due to their cost advantages, ease of manufacturing, and reliability. Although single sided PCBs are less complex than multilayer boards, they remain the preferred solution in many consumer electronics, industrial control, and simple power applications. With continuous innovation in materials and manufacturing technologies, as well as the driving force from emerging fields like IoT, single layer PCBs will continue to play a key role in meeting the ever-changing market demands.

Want to learn about the single sided PCB assembly process? Our comprehensive guide, 《PCB Assembly - A Comprehensive Guide》, provides the detailed information you need. Whether you are beginners  or experts, you'll find valuable insights here.