•This paper presents the design, simulation, fabrication and basic testing of non-spiral based fluxgate sensor.•This fluxgate sensor simulated using Ansys Maxwell software.•Fabricated using the PCB technology.•Tested the sensor using the measurement setup by using the Function generator, Oscilloscope and BPF filter.•Observed that sensor detects the strength of Earth’s magnetic field and plotted the frequency response of the sensor. This paper presents performance characteristics of non-spiral planar excitation and pick-up micro-coils implemented for a fluxgate sensor with a NiFe magnetic rod core.Using Ansys Maxwell's software, the sensor performance is simulated. Magnetic fluxϕ, magnetic flux density B, magnetic field intensity H, coupling coefficient, inductance L and magnetic energy E of the coils are simulated for a set of excitation currents. A simple, cost-effective and less complex fabrication method is implemented to fabricate the sensor using Printed Circuit Board (PCB) technology. Non-spiral 5-turn fluxgate sensor of dimensions 50mmx 20mmx 0.5 mm length × breadth × width is fabricated and analysed at an excitation current with a fundamental frequency of 500 kHz. Two excitation coils and one pick-up coil are deposited on a horizontal PCB plane and NiFe rod type material is placed on it, which acts as the core. Synthetic glue is spread on the coils; it acts a insulator between the coils and the core. Copper is used for deposition of the both the excitation and pick-up coils. On applying different excitation current, the frequency response of the non-spiral fluxgate sensor is plotted. The sensor demonstrated earth magnetic field strength detection (∼25 μT).