PCBA clone from physical board is a hands-on reverse-engineering process that focuses on replicating every aspect of a physical PCBA, from its component placement to its electrical functionality. Unlike cloning from design files, this method relies entirely on the physical board as the primary reference, making it essential for scenarios where documentation is lost, incomplete, or proprietary. The process starts with a thorough teardown and analysis of the physical board. First, the board is visually inspected to document its overall dimensions, shape, and the location of mounting holes, connectors, and components. Technicians then use precision tools to record the part numbers, values, and orientations of each component—this includes passive components (resistors, capacitors), active components (microcontrollers, ICs), and electromechanical components (switches, connectors). To reverse-engineer the board’s schematic, technicians use a combination of manual tracing and automated tools: for example, a continuity tester is used to map the connections between component pins, while software tools can scan the board’s surface to identify trace paths and generate a preliminary schematic. Once the schematic is complete, the next step is to create a layout that matches the physical board exactly—this involves replicating the trace width, spacing, layer stack-up (for multi-layer PCBs), and component footprints. The layout is then converted into Gerber files, which are sent to a PCB manufacturer to produce the base board. After the base board is manufactured, components are sourced to match the original physical board (preferably using identical part numbers to ensure compatibility) and soldered onto the board using surface-mount technology (SMT) or through-hole technology (THT), depending on the original board’s design. The final step is comprehensive testing: the cloned PCBA is tested for electrical continuity, component functionality, and overall performance to ensure it is identical to the original physical board. This includes testing under different operating conditions (e.g., varying voltages, temperatures) to confirm reliability. As with all PCBA cloning processes, legal compliance is crucial—cloning a physical board that is protected by patents, trademarks, or copyrights requires proper authorization to avoid infringement claims.