WEEK 08 Electronics Production

GROUP ASSIGNMENT:

FITCAM

I downloaded FLACAM software for the PCB CNC milling from https://bitbucket.org/jpcgt/flatcam/downloads/

My instructor Ricardo gave me this SVG line test.

LineTest_Clean_Inkscape.svg

In Flatcam just drag and drop the file and double click the geometry

I changed those values. You can hold the cursor over and it will give you explanations. Finally create a CNC job

From here we can see the traces and we can generate a G-CODE file

CANDLE

I downloaded from https://github.com/Denvi/Candle

check connection of your USB port with the machine
Drag and drop the g-code file and set up the probe test
I used arrows on the side to move the drill to my XY ZERO. I used a piece of paper to determine my Z ZERO (moving the frill down with very small step till the paper is squeezed tight between the plate and the drill but still possible to remove) ATTACH THE PROBE CLIP TO THE MILL AND PRESS PROBE
VERY IMPORTANT: REMOVE THE PROBE FROM THE ENDMILL!
I went to EDIT, and the I pressed SEND and unpressed the PAUSE button that is automatically ON after sending the file to the machine
After seeing the milling decided to ABORT the process because I didn’t like the result. I lover the Z 0.01mm down. I moved also XY to a new ZERO location and SEND it again
As you can see there were few tests (because I didn’t activate the heigh map and was trying to compensate with changing the Z depth and slowing down the feed rate)
It’s very important to activate the HEIGHMAP that is not automatically ON

CHANGING THE COPPER PLATE

I downloaded The GSENDER program to clean up and level up the CNC’s workspace https://github.com/Sienci-Labs/gsender/releases

The program is very intuitive. You need to be disconnected from other programs

Remove the old copper board

Apply the levelling milling bit

I put the CNC to a box to make less mess 🙂

Obviously some mistakes were done. As well as my surface was a bit tilted because of the guides that felt down (you can see horizontal lines on the MDF piece)

But after putting them back on and running the program again. Everything looks perfect. The hole wont bother me for now.

Time to put a new v-shaped end mill

In the meantime I practiced soldering on the old copper board

Attach double tape and place it on the CNC

Remember to solder the new copper board to the probe

BOARDHOUSE

To make a professional fancy boards you can visit https://jlcpcb.com/

Here’s a simulation:

INDIVIDUAL ASSIGMENT:

PCB PRODUCTION:

KICAD EXPORT

After designing the board in KiCad I exported the files. Firstly the paths and cut-out

You need to choose layers (copper lines and edge cut-out)

Next the drill holes

FITCAM PREPARATION

Drag and drop 3 files exported from KiCad. Select them all and move to the canter.

Select the fist one (double click) and choose CUTOUT TOOL

I choose those settings (holding cursor over the function, it gives explanation) and CREATED GEOMETRY

In the PROJECT TAB select the geometry (double click)

I choose those settings and GENERATE CNC JOB

Now I confirm that everything looks ok and SAVE G-CODE

Time to set up the paths. Double click the second file.

ISOLATION ROUTING and GENERATE GEOMETRY

I choose those settings and GENERATE CNC JOB

But there’s a problem, the drill won’t pass everywhere because of its thickness. I need to change the drawing.

Back to KiCad, save again, delete the old file, update the new one, place in the same spot and now it works good.

GENERATE the CNC JOB and after SAVE THE G-CODE

Time for the drill holes, back to the PROJECT TAB, double click Excellon file

Choose Drilling Tool

I change those settings and generated CNC JOB

Save the G-CODE

FINAL PROJECT:

That’s a great online G-CODE visualizer, for checking if everything is fine with the code before running it into the machine

https://ncviewer.com/

CANDEL CUT OUT

For the circuit I followed the same steps as in the LINE TEST And for the cot-out I change the milling bit

Made a new Z ZERO with probe clip

Remove the PCB with spatula

Cleaned with alcohol

And started soldering

Unfortunately I destroyed some lines and needed to use cable. But after checking with multimeter there were some unwanted connections

So I needed to unsolder and make a new one

After few more tries and mistakes I finally got my boards

RUNNING PROGRAM:

CAT BUTTON PCB

I made again same circuit in Wokwi and edited my code from week 4 to show ON and OF in the serial monitor

PUSH BUTTON (pull up resistor)+ LED

const int buttonRed = D9;
const int ledRed = D7;

void setup() {
  Serial.begin(115200);       // Start Serial Monitor
  Serial.println("Ready");    // Prints "Ready"

  pinMode(buttonRed, INPUT);  // Button not pressed = pin reads HIGH (due to the pull-up resistor)
  pinMode(ledRed, OUTPUT);    // Set LED pin as OUTPUT

  digitalWrite(ledRed, LOW);  // Start with LED OFF
}

void loop() {
  bool redState = digitalRead(buttonRed);  // Reads HIGH or LOW
  bool ledState = !redState;               // Invert to match LED behavior

  digitalWrite(ledRed, ledState);          // Controls LED

  Serial.println(ledState ? "ON" : "OFF"); // Prints "ON" or "OFF"

  delay(100);
}

SOS LED BLINK (by chat GPT)

const int ledRed = D7;

void setup() {
  Serial.begin(115200);
  Serial.println("Ready");
  pinMode(ledRed, OUTPUT);
}

void loop() {
  // SOS in Morse Code: "... --- ..."

  // Three short blinks
  for (int i = 0; i < 3; i++) {
    blinkLED(200); // Short blink (200ms ON, 200ms OFF)
  }

  // Three long blinks
  for (int i = 0; i < 3; i++) {
    blinkLED(600); // Long blink (600ms ON, 200ms OFF)
  }

  // Three short blinks again
  for (int i = 0; i < 3; i++) {
    blinkLED(200); // Short blink (200ms ON, 200ms OFF)
  }

  delay(2000); // Pause before repeating SOS signal
}

void blinkLED(int duration) {
  digitalWrite(ledRed, HIGH);
  delay(duration);
  digitalWrite(ledRed, LOW);
  delay(200);
}

REWARD MACHINE PCB

I did the same for my Reward Machine PCB

PUSH BUTTON (pull down resistor) + LED

const int buttonRed = D9;
const int ledRed = D6;

void setup() {
  Serial.begin(115200);
  Serial.println("Ready");

  pinMode(buttonRed, INPUT);  // Button with pull-down resistor (LOW when not pressed)
  pinMode(ledRed, OUTPUT);    

  digitalWrite(ledRed, LOW);  // Start with LED OFF
}

void loop() {
  bool redState = digitalRead(buttonRed);  // Reads HIGH when pressed, LOW when not

  digitalWrite(ledRed, redState);          // LED follows button state directly

  Serial.println(redState ? "ON" : "OFF"); // Prints "ON" when button is pressed, "OFF" when not

  delay(100);
}

SOS LED BLINK

const int ledRed = D6;

void setup() {
  Serial.begin(115200);
  Serial.println("Ready");
  pinMode(ledRed, OUTPUT);
}

void loop() {
  // SOS in Morse Code: "... --- ..."

  // Three short blinks (S)
  for (int i = 0; i < 3; i++) {
    blinkLED(200); // Short blink (200ms ON, 200ms OFF)
  }

  // Three long blinks (O)
  for (int i = 0; i < 3; i++) {
    blinkLED(600); // Long blink (600ms ON, 200ms OFF)
  }

  // Three short blinks (S)
  for (int i = 0; i < 3; i++) {
    blinkLED(200); // Short blink (200ms ON, 200ms OFF)
  }

  delay(2000); // Pause before repeating SOS signal
}

void blinkLED(int duration) {
  digitalWrite(ledRed, HIGH);
  delay(duration);
  digitalWrite(ledRed, LOW);
  delay(200);
}

FILES:

KICAD

REWARD MACHINE:

REWARD_MACHINE2.ZIP

BUTTON:

BUTTON2.ZIP

FLATCAM

REWARD MACHINE:

[REWARD_MACHINE_FC.ZIP

BUTTON:

BUTTON_FC.ZIP

CHECKLIST:

Group assignment:

Characterize the design rules for your in-house PCB production process: document feeds, speeds, plunge rate, depth of cut (traces and outline) and tooling.
Document the workflow for sending a PCB to a boardhouse
Document your work to the group work page and reflect on your individual page what you learned

Individual assignment:

Make and test a microcontroller development board that you designed

Learning outcomes:

Described the process of tool-path generation, milling, stuffing, de-bugging and programming
Demonstrate correct workflows and identify areas for improvement if required

Have you answered these questions?

Documented how you made the toolpath
Documented how you made (milled, stuffed, soldered) the board
Documented that your board is functional
Explained any problems and how you fixed them
Uploaded your source code
Included a ‘hero shot’ of your board