Assignment: Computer-Controlled Machining

Individual assignment

• make (design+mill+assemble) something big (~meter-scale)
• extra credit: don't use fasteners or glue
• extra credit: include curved surfaces

Introduction

To fulfill the requirements of this assignment, I explored kerf bending techniques, which allow bending rigid materials like plywood by introducing precise cuts. This technique enabled the creation of curved surfaces without complex steam bending or laminated molds.

Learning Path

Kerf Bending Techniques – Used for adding flexibility to rigid materials.

Living Hinges – Implemented for creating seamless curves in plywood using laser cutting.

Parametric Design Considerations – Experimented with different kerf patterns and spacing calculations using online tools.

Schematic Diagrams :

Since I had never worked with an EDA tool before, I referred to multiple tutorials to understand how to read schematic diagrams. To get comfortable with KiCad's workflow, I worked through the example files available on the KiCad learning page. This helped me understand the step-by-step design process, which includes:

KiCad Workflow :

• 1. Creating the Schematic Diagram - Drawing the circuit diagram using symbols for different components.

• 2. Assigning Component Values - Specifying values for resistors, capacitors, and other elements.

• 3. Assigning Footprints - Selecting the physical package for each component.

• 4. Running the Electrical Rules Check (ERC) - Identifying and resolving electrical connection errors.

• 5. Converting the Schematic to PCB Layout - Transferring the schematic into the PCB editor.

• 6. Placing Components and Routing Traces - Ensuring an optimal layout for signal flow and power distribution.

• 7. Running the Design Rule Check (DRC) - Validating trace widths, clearances, and manufacturing constraints.

• 8. Generating a 3D Render View - Visualizing the final board before exporting for fabrication.

Project Inspiration :

For my first project, I wanted to design a Temperature & Humidity Sensor Board that integrates an ESP8266 microcontroller and a DHT11 sensor. I was inspired by existing projects that combine these two components into a single PCB for data collection and wireless communication.

• 1. Collecting Schematic References: I searched for open-source schematic designs for the ESP8266 and DHT11.

• 2. Creating the Schematic in KiCad: I drew the circuit in KiCad on a single-page schematic file, ensuring all connections were correctly placed.

• 3. Running ERC: I conducted the Electrical Rules Check (ERC) and cleared all errors

• 4. Converting to PCB Layout: After validating the schematic, I transferred it to the PCB editor.

• 5. Performing DRC Check: I verified trace widths, spacing, and other design rules to ensure manufacturability.

• 6. 3D Render View: Finally, I used KiCad's 3D viewer to visualize my design before exporting it for manufacturing.

Conclusion :

Through this assignment, I gained hands-on experience with KiCad, learning how to design a PCB from start to finish. The step-by-step workflow allowed me to understand schematic design, PCB layout, and the essential verification processes. This project has given me confidence in working with EDA tools, and I look forward to developing more complex designs in the future.