Week 04

Electronics Production

February 22 2022

About the Class

In both the local and global class we were introduced into the theoretical concept and process of PCB milling and soldering. This extended into a hands-on introduction of soldering top-mounted components on PCB boards and handling the Roland SRM-20 mill. More on the details below.

Learning how to solder

After a theoretical introduction, we were given the chance to practice soldering hands-on. For that, we had special text boards with varying practical difficulty throughout board. After the intro, I had the chance to solder a lot more as it turned out: By building a 4-track collaborative loop station in the Fab Academy challenge week, we needed some 30+ connections to be soldered. After a couple of hours, I became more confident and quicker with soldering.

Eduardo explaining the ways to correctly place and solder components on a milled PCB board.

Joaquin practicing on the soldering test board.

The result of practicing on the test board under a magnifying glass. From left to right, the quality of the solder connections can be seen (although still not incredibly great).

Honing my soldering skills during the first Fab Academy Challenge, soldering some 30+ connections.

PCB Design and Milling

As for the custom PCB design and milling, one of the most important concepts is to understand how the drill moves across and through the copper layer on the substrate plate. To prepare high-resolution PNGs or SVGs for milling, we generate Gerber-files via Modsproject, which is a node-based formatting online tool developed and open-sourced by the MIT. In order to generate the files for the specific mills at the FabLab BCN, we need to open a new program (right click on canvas) and select Roland SRM-20 mill > PCB Absolute as settings.

After soldering for a while during the first Fab Academy challenge week, the next step for the loop station should be to design a custom PCB board to reduce the amount of cables and the need for a breadboard. This will allow for a better layout of the components and a smaller physical footprint, since it can be implemented as a shield for the Raspberry Pi 4. I'm currently diving into Fritzing to learn how to design such a board exactly.

The modsproject nodes for processing a PCB design for the Roland SRM-20 mill.

Getting started designing a custom Raspberry Pi shield in Fritzing.

Further Links

PCB fabrication
etching
lithography, transfer
     ferric/cupric chloride, ammonium/sodium persulfate
citric acid, peroxide
SDS
water consumption
waste
machining
machines
     tools
0.010
1/64
1/32
V-bits
tapered bits
contouring bits
     fixturing
     underlay
     orientation
     zeroing
     set-screws
     lifetime
     deburring
     cleaning
     climb vs conventional
vinyl cutter flex connections encapsulation milling
laser cutter
printing conducting inks
plating
sewing

PCB materials
  rigid
     FR4 (epoxy glass)
FR1 (phenolic paper)
garolite
  flex
Kapton, Pyralux
#1 epoxy film, #1126 copper tape
  high-frequency
     teflon
     glass
  copper
     0.5 oz: 17.5 um
     1.0 oz: 35 um
     2.0 oz: 70 um

board houses
OSH Park, JLCPCB,
DKRed, Advanced, PCB:NG, Sierra, Screaming Circuits,
PCBWay , AQS, Gold Phoenix, 3PCB, Seeed,
Think & Tinker
     PCB, kit, BOM
  design rules
     width/spacing (15, 5 mils)
  layers
1, 1.5, 2, 2+, 4, N
  mechanical, drill, solder mask, silk screen
  vias
rivets, plated, blind, buried

components
  through-hole
  surface-mount
  chip-scale

breadboards

assembly
solder
iron station fume extractor
ROHS
types
        lead-free wire paste SDS
        leaded wire paste SDS
        low-temp wire paste
     eutectic
wetting
manual, drag, wave
cold solder joints
     flux core, paste, pen
     reflow
hot air, hot plate, oven, IR
     magnifying
  stuffing
     component orientation
     tacking down parts
     bottom to top, inside to outside
     fumes
     washing
desoldering
braid
vacuum
hot air
     gravity
  cutting traces, adding jumpers
pick-and-place
  encapsulation

CAM
  formats
Gerber/RS-274X
png resolution
FlatCAM
cam.pycad.pykokompefab modulesmods community edition
video
  trace width
traces interior 1/64" 0.010" fiber laser

assignment
group assignment:
     characterize the design rules for your in-house PCB production process
     extra credit: send a PCB out to a board house
individual assignment:
     make an in-circuit programmer that includes a microcontroller:
        extra credit: customize the design
        mill and stuff the PCB
        test it to verify that it works
        extra credit: try other PCB processesamet, consectetur adipiscing elit. Suspendisse varius enim in eros elementum tristique. Duis cursus, mi quis viverra ornare, eros dolor interdum nulla, ut commodo diam libero vitae erat. Aenean faucibus nibh et justo cursus id rutrum lorem imperdiet. Nunc ut sem vitae risus tristique posuere.