Electronics Production
File preparation - CopperCAM
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In order to fabricate my circuit I opened the CopperCAM software. I created a New circuit - File>Open>New circuit
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I imported the front layer - F_Cu.gbr file.
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I right-clicked on the intended contour - the outer edge and clicked Define as card contour, setting it to outside contour (inside for any intended negative spaces)
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In File > Dimensions I set the margin to 1mm and Z thickness to 1.6mm around 0.1-0.2 more than the measured stock thickness
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In File > Offset I set the Origin to X:0, Y:0 mm
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In File > Open I clicked Additional layer, as I had one more layer to add to the circuit - the drilling holes NPTH gerber file
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The layer didn't align as supposed - so I used the Reference pad option to align them
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In my design I had lines that were for a decorative purpose only - the cat whiskers. In order to have then engraved only with one pass of the tool, I selected them, right clicked and clicked Engrave tracks as centerlines
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I proceeded to set up the tool necessary for the job - Parameters>Selected tools and filled as follows
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I selected the >Calculate contours option to create the toolpaths and chose 4 passes
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In order to save the files, I clicked the Mill option and filled the pop up window as follows. This way I got 4 .gbr files
VCarve and the board milling
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I cleaned the workspace and the inside of the machine with a vacuum cleaner in order to avoid any dust that could interfere with my milling later on
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I carefully measured the thickness of my stock material
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In order to make soldering easier, I removed the top layer covering the copper - by scratching it with metal wire
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I put double-sided tape on the back side of the stock. It should be perfectly flat, no bubble like below, no overlapping, no dust
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I placed the stock on the board attacched to the machine bed, again trying to make it as flat as possible
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I checked if the bits I intended to use were not broken
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I placed the engraving 0.35 bit in the spindle (as far as possible) and temporary secured it with srewing it with the designated tool
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I opened the VPanel software and using the arrow buttons, I moved the spindle to the intended XY origin position (botttom left / south-west) over the stock. I clicked Set origin point > User coordinate system > XY
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Low above the stock surface, I released the screw holding the tool tip for it to move down with gravity and touch the copper surface. I then tightened it again and clcked Set origin point > User coordinate system > Z
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In Vpanel I clicked Cut and opened the first tool toolpath - engraving .egx file. I clicked Output to start the milling process
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To perform the second operation - the drilling and then cutting - I had to change the bit to the 0.8mm one. I repeated the same process to set the new Z origin. Important - set the new origin pointONLYfor Z position leaving the original XY, otherwise the drilling and cutting would not be aligned
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I got my board milled. I cleand all the dust with the vaccum cleaner and removed the tape
Fail gallery
It took a lot of tries to actually get the board milled properly
![sshkeys](../media/electronicsproduction/one.jpg)
I included the Silscreen layer as I thought that was the way to get the graphics layer. Mistake. Any additional graphics should be added to the front/bacl copper layer and then set as Engrave tracks as centerlines option in CopperCAM
![sshkeys](../media/electronicsproduction/one2.jpg)
![sshkeys](../media/electronicsproduction/two.jpg)
Too deep
![sshkeys](../media/electronicsproduction/two2.jpg)
![sshkeys](../media/electronicsproduction/three.jpg)
Not deep enough
![sshkeys](../media/electronicsproduction/three2.jpg)
![sshkeys](../media/electronicsproduction/four.jpg)
Uneven depth, some tracks cut through
![sshkeys](../media/electronicsproduction/four2.jpg)
![sshkeys](../media/electronicsproduction/five.jpg)
Just right
![sshkeys](../media/electronicsproduction/five2.jpg)
![sshkeys](../media/electronicsproduction/all.jpg)
Soldering
![sshkeys](../media/electronicsproduction/soldering.jpg)
![sshkeys](../media/electronicsproduction/wrongSide.jpg)
![sshkeys](../media/electronicsproduction/soldered.jpg)
![sshkeys](../media/electronicsproduction/solderedDetail.jpg)
![sshkeys](../media/electronicsproduction/solderedDetail2.jpg)
Testing the board
I tested the board out with the updated code I prepared as the Embedded Programming assignment. Pictured below is the board working in the Networking assignment