How to make PCB - Speaker Deck

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HOW TO MAKE PCB edited by Yongwoo Song Y Eduardo Chamorro USING SRM-20, Small Milling Machine

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1. What is PCB 2. PCB Production 3. PCB Endmill 4. SRM-20 Operation 5. Practice INDEX

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WHAT IS PCB?

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WHY WE NEED PCB ?

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WHY WE NEED PCB ? 1970’s Hand-drawn circuit board

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WHY WE NEED PCB ? DIY Flexible board

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WHY WE NEED PCB ? From clothes to everything (Best for wearable devices)

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http://fab.cba.mit.edu/content/tools/shopbot/index.html FAB ISP PROGRAMMER KEY

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TYPES OF COPPER BOARD FR4 : Epoxy resin (fiber glass), multiple layer (multiple use) double sided or more can be fabricated FR1 : Phenol resin (paper fiber), less hardened than FR4 single sided board

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CHOOSING THE BOARD TYPE 1. Check if it is power circuit / signal circuit 2. If SMD components are needed or not 3. If there are too many components for difficult wiring 4. What’s the final goal for the price

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STRUCTURES OF PCB

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STRUCTURES OF PCB

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PCB PROTOTYPE

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PCB PROTOTYPE

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PCB IMPLEMENTATION (LDS)

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LDS TECHNOLOGY HIGH-END TECHNOLOGY IMPLEMENTATION

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PCB PRODUCTION

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ETCHING Hard to control the procedure Lots of waste control

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CNC MILLING PCB Fixture needed, High quality Tool change needed, breakage of end-mills

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High quality with high speed No tool change FIBER LASER CUT PCB

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FIBER LASER CUT PCB High quality with high speed No tool change

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VINYL CUT PCB Vinyl cut PCB

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VINYL CUT PCB Lots of implementation , Poor quality, Short lifetime usage

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PCB ENDMILL

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KNOWING THE END-MILL

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KNOWING THE END-MILL

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KNOWING THE END-MILL COMPUTER CAN’T MAKE TOOL PATH WITH NARROW PATH

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FAB MODULES

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SELECT THE INPUT FORMAT USE .png for Eagle files USE .stl files for 3D Toolpath.

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CHOOSE OUTPUT FORMAT

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SELECT PROCESS (TRACES, OUTLINES)

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SELECT SUITABLE MACHINE TO MAKE CODE

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- Recommended feed rate of mills - Making Traces : 3.5 ~ 4 mm/s Outline Traces : 0.5 mm/s SPEED CALCULATION

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OFFSET DIFFERENCE NO. OFFSETS : 4 NO. OFFSETS : -1 (TO COVER)

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FAB MODULE INTERFACE 1. Check Machine 2. Feed Rate setting 3. X, Y, Z origin 4. Calculate 5. Save

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SRM-20 OPERATION

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POWER THE DEVICE ON

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SELECT THE END MILL

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LOCK/UNLOCK THE COLLET Rotate Clockwise to LOCK !! Rotate Anti-Clockwise to UNLOCK !!

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FIXING THE COPPER BOARD MAKE SURE THERE ARE NO BLANK SPACES !!! DON’T TRY TO SAVE DUCT TAPE, SAVE COPPER BOARD ~

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Operate the V-Panel for SRM-20 MAKE THE USER COORDIANE ORIGIN !!!

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Operate the V-Panel for SRM-20 MAKE CLOSEST DISTANCE AND MAKE MANUAL Z !!!!

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Operate the V-Panel for SRM-20 1 2

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Operate the V-Panel for SRM-20

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Operate the V-Panel for SRM-20

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Operate the V-Panel for SRM-20

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Operate the V-Panel for SRM-20 1 2

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Operate the V-Panel for SRM-20 1 2

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SETTING ORIGIN POINT (USER COORDINATE SETTING) CHECK TO MAKE SURE ORIGIN POINT IS USER COORDINATED (ex G54) PRESS

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OUTPUT FILE SETTING START !!! OUTPUT FILE LIST MEANS ORDER OF FILES OPERATION

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MILLING COPPER BOARD

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MILLING THE BOARD STARTING TRACES (1/64”)

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TRACES OUTPUT CUT

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MILLING THE BOARD STARTING OUTLINES (1/32”)

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TAKE OUT THE BOARD USE CUTTING KNIFE FOR REMOVAL

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TAKE OUT THE BOARD FINAL RESULT

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TAKE OUT THE BOARD

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TAKE OUT THE BOARD

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TROUBLE SHOOTING 1. Bad Z offset 2. Worn End-mill 3. Lots of waste residue

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SOFTWARE

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MAKING THE PCB BOARD

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PADS LAYOUT

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Eagle CAD (SCHEMATIC VIEW)

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Eagle CAD (BOARD VIEW)

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INTERFACE LAYER MOVE INFO DELETE NAME WIRE VALUE SAVE SCH/ BRD RUN ULP

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Select layers that are needed for monochrome image Remember to edit some design with 2D design tools such as Photoshop / illustrator / GIMP etc.

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PRACTICE

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WHAT KIND OF WATCH DO YOU WANT

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USB ? OR WHAT ELSE

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WHAT WE NEED TOOLS - Roland SRM-20 - Computer with VPanel Installed - Soldering Iron -Flat end mills, 1/64” and 1/32”, -(If equipped) Flat end mills, 1/16” for clearing out all excess copper MATERIALS - Double-sided FR-1 PCB - Double-sided tape - Solder & Solder paste - Velcro straps (accesories) ELECTRONIC COMPONENTS - Atmel ATtiny chip (ATtiny 85) - LEDs (SMD) = Surface Mount Device components - Resistors, ~499 ohms (SMD) - Momentary button, square (SMD) - Coin cell battery, CR2032, 3-volt - Coin cell battery holder

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Order of making tool path FILES note : black for the end mill to recognize 1. (filename)_traces.png

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Order of making tool path FILES 2. (filename)_holes.png 3. (filename)_outlines.png

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Edit with Photoshop if necessary , 40PX at least for the 1/64 mill to pass through

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ARTWORK WITH EAGLE

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MAKING OUTLINES OF CUSTOM DESIGNED PCB

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MAKING OUTLINES OF CUSTOM DESIGNED PCB

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OBJECT - PATH - ADD ANCHOR POINTS Add as enough amount to know the outline of the drawings Save the file in dxf RT13 format!!

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NOT ENOUGH ANCHOR POINTS

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RUN ULP for POLYGON IMPORT run : import_dxf_polygons.ulp find .ulp files in the explorer

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RUN ULP FOR IMPORTING VECTORS import_dxf_polygons.ulp is available at GitHub for windows put the .ulp file in C://Program files/Eagle

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OPEN THE DXF FILE MADE WITH ILLUSTRATOR

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DIFFERENCE BETWEEN POLYGON AND WIRE

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DIFFERENCE BETWEEN POLYGON AND WIRE

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MAKE FINAL ADJUSTMENTS WITH WIRE

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SOLDERING TO FINISH!!!

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SOLDER PASTE FLUX HELPING AGENT SOLDERING PASTE

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1. Use a good soldering iron (cordless, temperature-controlled…) 2. Correct type of vice or third hand 3. Use the thinnest solder appropriate for the project 4. Use the right-size time for the project 5. Allow the soldering iron the reach the right temperature 6. Apply the iron to the joint first then solder to allow the spread. 7. Don’t put too much solder … bigger the blob, more trouble 8. Tin your wires by placing small solder first and wipe it off 9. Clean the tip often with iron wool, a wet sponge and tip cleaner 10. Don’t apply pressure on the soldering iron 11. Don’t move the joint while its cooling and don’t blow it 12. Practice on scrap before starting the joint, and practice practice !!! SOLDERING TIPS

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1. Don’t burn yourself 2. Don’t burn anything else 3. When you burn yourself - because you will - be sure to have first aid kit 4. Wear pants to protect your legs, safety glasses 5. Don’t wear polyester clothing 6. Work in a clean area free of oils, grease and anything that is flammable 7. Solder slowly and stay focused 8. Always return the soldering iron to the stand after each use 9. Remember !!! It takes a long time for the soldering iron to cool off 10. Always unplug the soldering iron when you’re done SOLDERING SAFETY

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REFERENCE http://todbot.com/blog/2011/06/06/from-illustrator-to-eagle-vector-graphics-in-circuits/ https://en.wikipedia.org/wiki/Printed_circuit_board http://archive.fabacademy.org http://www.jameco.com/jameco/workshop/techtip/soldering-tips.html http://www.hobbyelectronics.net/tec_makingdoublesidedpcbs.html http://www.eevblog.com