What Is PCB Cloning?
PCB cloning is the process of producing a working duplicate of an existing circuit board — one that behaves the same, fits the same enclosure and uses the same connectors. Where reverse engineering delivers design data, cloning delivers hardware: a board you can install and run.
We start from the physical board, reconstruct its design data, match every component to a currently procurable equivalent, and then fabricate and assemble the replacement. Since 2011 this has been the way our customers keep discontinued equipment alive — from a single rescue board to small production runs of a few hundred units per year.
What a PCB Clone Includes
| Item | Detail | Why it matters |
|---|---|---|
| Bare boards, new fabrication | Gerber data verified against the original | No reliance on salvaged or refurbished stock |
| Component selection | Every part identified; obsolete parts matched to equivalents | You are not left with a board nobody can build |
| Assembly | SMT and through-hole, with your approval on substitutions | Ready to install, not a kit |
| Programmed parts | Where lawful, firmware duplicated to the same parts | The clone behaves like the original, not just looks like it |
| Functional test | Each clone tested against your original unit | Proof it works before it reaches your floor |
Cloning is the right choice when the board itself is the bottleneck — when you cannot buy it, cannot repair it any longer, and cannot wait for a redesign.
When You Need PCB Cloning
- A discontinued controller has failed — and the OEM no longer sells, repairs or supports it.
- Spare-part supply has dried up — you are down to the last board on the shelf, and the next failure stops production.
- You need a second source — the original vendor is too slow, too expensive, or has exited the market.
- A fleet of identical machines needs long-term support — one clone project covers every unit you run.
- You want to hold stock instead of scrambling — once the design data is verified, repeat boards are fast and inexpensive.
Our Cloning Process
- Assessment and fixed quote — you send photos of both sides, plus a note on the equipment the board runs in. We confirm layer count, board size and density and quote a fixed price, usually within one business day.
- Design data reconstruction — the board is imaged and rebuilt as accurate layout and schematic data, exactly as in a reverse engineering project.
- Component identification and matching — every part is read, identified and matched. Obsolete parts are replaced with pin-compatible or functionally equivalent alternatives, listed for your approval.
- Approval before build — you see the substitution list and the design data summary before anything is manufactured. Nothing is built on assumptions.
- Fabrication and assembly — new bare boards are made from the verified data, then populated on our assembly line, SMT and through-hole.
- Functional test against your original — every clone is powered up and tested against the unit you supplied, so you know it behaves identically before it ships.
A typical cloning project runs one to three weeks including assembly, depending on component lead times. The schedule is confirmed in writing with the quote.
Component Obsolescence and Sourcing
This is the part that decides whether a cloning project succeeds. A clone that uses parts nobody can buy is a dead end, so component work is where we spend the most care:
- Full identification — markings, package, pinout and electrical characteristics for every part on the board
- Procurable equivalents — where the original is obsolete, we propose a currently stocked alternative with the same function and footprint
- Pin-compatible options flagged — so you can see at a glance which substitutions are drop-in and which need a small change
- Your approval, always — substitutions are listed and approved by you before assembly, never swapped silently
Where a part is genuinely unobtainable, we tell you early rather than after the boards are made — and where the alternative requires a small board change, we say so before you commit.
Firmware and Programmed Devices
Many boards carry a microcontroller, EEPROM or PLD that has to contain the right code for the board to function. Where you are the lawful owner of the device and its software rights, we can extract and duplicate that firmware as part of the cloning project, then program the same devices during assembly.
Tell us the situation when you request the quote — whether the firmware is yours, whether you hold the source, and whether the part is protected. We will tell you honestly what is possible before you commit to anything.
Cloning vs Copying vs Reverse Engineering
The three services overlap, but they end in different places:
| PCB cloning | PCB copy | Reverse engineering | |
|---|---|---|---|
| You receive | A working board, assembled | Bare-board fabrication files | Design data: schematic, Gerber, BOM |
| Components fitted | Yes | No | No |
| Schematic included | On request | No | Yes |
| Best for | Replacing an unobtainable board | Making bare boards quickly | Understanding or modifying a board |
If you need the design data rather than hardware, see our PCB reverse engineering service. If you only need bare boards, see our PCB copy service.
Production Quantities and Repeat Orders
Once the design data has been verified, cloning stops being a project and becomes a supply line. Repeat orders are fast and inexpensive because the hard work — reconstructing the design and clearing the component list — is already done.
- Single rescue unit — one board to get a machine back into service
- Spare-part stock — five or ten boards on the shelf, so the next failure is a shelf pick rather than an emergency
- Small production runs — repeat builds on a schedule, at a per-unit cost far below the first article
How Much Does PCB Cloning Cost?
Cloning has two cost components, and it is worth understanding both before you request a quote:
- One-time engineering — reconstructing the design data and clearing the component list. Driven by layer count, board size and component density, exactly like reverse engineering.
- Per-unit build cost — bare board fabrication, components and assembly. Driven by component price and quantity.
The engineering cost is paid once. Every board after the first carries only the build cost, which is why cloning a fleet of machines almost always pays for itself. Send photos of both sides of the board and we will return a fixed quote with both numbers broken out, usually within one business day.
Why Circuit Engineer
- Cloning and reverse engineering PCBs full-time since 2011, for customers worldwide
- Every clone is functionally tested against your original before it ships
- Component obsolescence handled openly — you approve every substitution before assembly
- Strict confidentiality: we work under NDA on request and never reuse or resell customer design data
- Fixed quotes, and a single point of contact from assessment through to repeat orders
Related work: cloning service for engine control unit (ECU) boards.
Frequently Asked Questions
Will the clone look identical to the original?
Electrically and functionally, yes — same dimensions, same mounting, same connectors and same behaviour. Visually there may be minor differences such as silk-screen font or solder-mask shade, unless you specifically require a cosmetic 1:1 match, which we can also do.
What if components are obsolete?
We identify every part and propose currently procurable equivalents. Substitutions are always listed and approved by you before assembly — never silently swapped.
Can you clone the firmware too?
Where you are the lawful owner of the device and its software rights, we can extract and duplicate firmware as part of the cloning project. Tell us the situation when requesting a quote.
How many clone boards can you produce?
From a single rescue unit to small production runs. Once the design data is verified, repeat units are fast and inexpensive.
How long does a cloning project take?
Typically one to three weeks including assembly, depending on component lead times. The schedule is confirmed in writing with the quote, before any work starts.
Can you clone a board without the original documentation?
Yes — that is the normal case. The physical board is the source of truth, and we reconstruct everything from it.
How do we start?
Send photos of both sides of the board plus a description of the equipment it runs in, through our contact page. You will receive a fixed quote, usually within one business day.
Get Your Clone Quote
Two clear photographs — top and bottom — plus a note on what the board controls are enough to start. Send them through our contact page and we will reply with a fixed price and schedule. No obligation, full confidentiality.
Related guides
- How the process works — the seven stages every project follows, in order.
- What it costs — real price ranges by board type and deliverable scope.
- Obsolete components — what to do when a part on the board no longer exists.
- Schematic recovery — recovering the circuit behind the board you need cloned.
- PCB reverse engineering — the wider service this sits inside.
We also clone and reverse engineer boards from specific sectors: automotive, medical, industrial control, aerospace and defence, and consumer electronics.