How to Fix Broken PCB Traces?

August 29, 2025

Innovations in electronics are occurring rapidly, with devices constantly competing to be the lightest, most specs-packed and least costly in the market. Inside these devices are dense circuits mounted on a dielectric substrate known as the Printed Circuit Board or PCB. As these circuits are becoming more densely populated, failures can happen, which can be derived from manufacturing and design or even acquired during handling and application. For instance, one frequent concern is how to fix broken PCB traces, which directly affects functionality and reliability.

We will discuss one of the common repairs being done on a defective PCB. Knowing how to fix broken PCB traces is important, as it is one of the most common issues in printed circuit boards. Spend some time to read below information about fixing PCB traces to fully restore back to good condition of the circuit board.

What is PCB Trace?

A PCB trace is a conductive channel that serves as an electrical and thermal pathway for electronic components. Traces are typically made of copper material due to their good electrical and thermal conductivity, availability and low cost. The key design parameters in a PCB trace include width, length, thickness and spacing. These items should be optimised as they directly affect the current carrying capacity of the trace and its susceptibility to Electromagnetic Interference or EMI.

How to Diagnose a Broken PCB Trace?

https://www.qfpcb.com/high-volume-pcb-assembly/The increasing complexity in PCB design resulted in tighter pitches and narrower trace widths, which also present a challenge in PCB trace repair. Take note of below PCB diagnostic techniques below in pinpointing a broken PCB trace, as these are crucial in understanding how to fix broken PCB traces.

Conduct Visual Inspection.Inspect the PCB under a Luxo lamp or with the aid of a magnifying glass.

Check for any visual anomalies like damage or burn signs.
If it is difficult to spot the broken trace, inspect further using higher magnification through a microscope. This step is often an essential part of learning how to fix broken PCB traces effectively.

Perform Basic Electrical Testing.Verify continuity of the circuit using a multimeter. Place the probes on the trace of concern to confirm the issue. A functional trace will reveal low resistance values, while a break on the trace will show incorrect values. Understanding these readings can directly guide you on how to fix broken PCB traces with accuracy.

Use of Advanced Methods. Other advanced diagnostic methods are also available, such as Automated Optical Inspection or AOI, X-ray inspection and Time-Domain Reflectometry or TDR.

AOI. It works by capturing and analysing high-resolution images of the PCB to detect issues such as nicks, breaks and open traces.
X-ray Inspection. Hidden issues, such as broken traces in the inner layer that are not visible to the human eye, can be screened out by X-ray.
TDR. A TDR is a type of electrical testing that utilises a high-speed electrical pulse to be transmitted down the copper trace to determine precisely the location of the break.

What are the Tools and Materials Needed to Fix a Broken PCB Trace?

The basic tools are discussed below to help visualise the workstation when fixing a broken PCB trace. Knowing the correct tools is a key step in mastering how to fix broken PCB traces.

Soldering Iron. A soldering iron is a temperature-controlled tool that is used to heat solder, traces and components. This tool is fundamental when demonstrating how to fix broken PCB traces successfully.
Multimeter. A multimeter is used to verify if the circuit is open due to a broken trace. This is used before and after the PCB repair process for continuity confirmation.
Visual Inspection Tools. Microscopes and magnifying glasses are both important tools in the proper identification of the trace spot where repair is necessary.
Cutting or Scraping Tool. Since the existing solder and trace must be cut or scraped away, a fibreglass pen or a sharp tool can be used to clean the area.
Jumper Wire. This is used to bridge the broken trace, usually made of an insulated wire to shield adjacent wires from shorting, making it an essential item in any guide on how to fix broken PCB traces.

How to Fix Broken PCB Trace?

There are many known techniques by which a broken PCB trace can be fixed. If you want to learn how to fix broken PCB traces, below are the two popular methods:

1. Jumper Wire Method

Perform some testing to confirm the broken trace.
Use a scraping or cutting tool to remove the solder mask.
At both ends of the break, apply a small amount of flux and tin. The flux helps in the removal of oxides and improves solderability.
Solder the jumper wire by stripping the insulation and applying solder.
Solder one end of the jumper wire to the copper with pre-solder. Do this again to the other end.
Protect the wire with a solder mask or an epoxy to prevent oxidation.
Using a multimeter, retest the circuit if the trace repair has been successful. This method is one of the most common steps when explaining how to fix broken PCB traces.

2. Epoxy Method

Clean and prepare the surface using a solvent.
Trim the damaged conductor trace using a sharp knife. This can be done with the assistance of heat from a soldering iron to remove the trace more easily.
Remove residues from the existing solder near the trace.
Apply flux and tin to the neighbouring area where the new trace will be applied. Align the replacement trace at the proper location.
Secure the new trace in place using an ESD tape. Apply flux on the solder joint and inspect if the trace is properly aligned.
Coat the bottom and overlap the trace with an epoxy. Cure the epoxy to achieve a good bond.
Check the new connection using a multimeter to ensure the continuity issue has been resolved.

What are the Guidelines for Fixing PCB Traces

It is also necessary to highlight the different guidelines to follow and mistakes to avoid when fixing PCB copper traces.

Anyone learning how to fix broken PCB traces must remember that the replacement trace must have the same dimensions and current-carrying capacity as the previous one.
Avoid excessive temperatures to prevent further damage to the traces or nearby components.
Conduct training of PCB repair personnel. Fixing a broken trace requires skills and practice, which must be demonstrated well before doing the actual repair.
Be careful not to induce damage to adjacent traces to prevent more catastrophic failures, as this is a critical step in mastering how to fix broken PCB traces.

Conclusion

The article has offered additional knowledge in fixing broken traces, which can be helpful in analysing and correcting PCB issues. Repairing a broken PCB trace is a more affordable and efficient solution than procuring a brand-new replacement. Find a quality-driven PCB manufacturer that can offer PCB troubleshooting and repair services. Viasion Technology is one of the reputable PCB manufacturers located in China that offers cost-competitive and fast turnaround PCB services. One of our core services includes troubleshooting and repairing broken PCBs.