Electronics Production

Hero Shot

Task: Electronics Production

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 Experience

    I concentrated on the design, milling, and assembly of a microcontroller development board this week in order to learn more about electronics production. I utilized the MonoFab SRM-20 for PCB milling and collaborated with Mods to create G-code from Gerber files. To guarantee a top-notch PCB manufacturing process, I also investigated surface preparation methods, cutting tool selection, and CNC machine operation via V-Panel.

    Key Accomplishments

    ✅The XIAO ESP32-C3 was used to design a microcontroller development board.
    ✅Mods were used to generate Gerber files and convert them to G-code.
    ✅ Used the SRM-20 to mill a PCB with accurate cuts and traces.
    ✅ Managed toolpaths and set origins while operating the V-Panel CNC milling program.
    ✅ The PCB was cleaned and prepared to guarantee a solderable surface.
    ✅ Acknowledged the significance of feeds, speeds, and bit selection in PCB manufacture.
    Individual Assignment:

    MonoFab SRM-20

    As a small milling machine, the SRM-20 offers compact size and powerful functionality at an affordable price. Production of realistic parts and prototypes is made simple and convenient with a device that fits into any office, studio, or classroom environment. For users looking for advanced milling capabilities without the need for expert operating skills, the SRM-20 is one of the easiest and most precise CNC mills in its class.

    Specifications
    Model SRM-20
    Cuttable Material Modelling Wax, Chemical Wood, Foam, Acrylic, Poly acetate, ABS, PC board
    X, Y, and Z Operation Strokes 203.2 (X) x 152.4 (Y) x 60.5 (Z) mm
    Workpiece table size 232.2 (X) x 156.6 (Y) mm
    Distance From Collet Tip to Table Max, 130.75mm (5.15 in)
    Loadable Workpiece Weight 2 kg (4.4 lb)
    X-, Y-, and Z-Axis Drive System Stepping motor
    Operating Speed 6 - 1800mm/min (0.24 - 70.87 inch/min)
    Software Resolution 0.01 mm/step (RML-1), 0.001mm/step (NC code)
    Mechanical Resolution 0.000998594 mm/step (0.0000393 inches/step)
    Spindle Motor DC motor Type 380
    Spindle Rotation Speed Adjustable 3000 - 7000 rpm
    Cutting Tool Chuck Collet method
    Interface USB
    Control Command Sets RML-1, NC code
    Power Requirements Machine: DC24V, 2.5A, Dedicated AC adapter: AC 100-240 V ±10%, 50/60 Hz
    Power Consumption Approx. 50 W
    Operating Noise During operation: 65 dB (A) or less (when not cutting), During standby: 45 dB (A) or less
    External Dimensions 451.0 (W) x 426.6 (D) x 426.2 (H) mm
    Weight 19.6 kg (43.2 lb)
    Installation Environment Temperature of 5 to 40°C (41 to 104 °F), 35 to 80% relative humidity (no condensation)
    Included Items USB cable, AC adapter, Power cable, Cutting tool, Collet, Set screw, Spanners (7,10mm), Hexagonal wrench (size 2,3 mm), Positioning pins, Double-sided tape, Start-up page guidance card


    monoFab SRM-20 Accessories
    Category Item Model Description
    End-mills Square end-mills ZHS-100 High speed steel dia. 1 3(l)×6(d)×50(L)×2NT
    Square end-mills ZHS-200 High speed steel dia. 2 6(l)×6(d)×50(L)×2NT
    Square end-mills ZHS-300 High speed steel dia. 3 10(l)×6(d)×50(L)×2NT
    Square end-mills ZHS-400 High speed steel dia. 4 12(l)×6(d)×50(L)×2NT
    Square end-mills ZHS-500 High speed steel dia. 5 15(l)×6(d)×55(L)x2NT
    Square end-mills ZHS-600 High speed steel dia. 6 15(l)×6(d)×55(L)x2NT
    Square end-mills ZHS-3015 High speed steel dia. 3 15(l)x6(d)x50(L)x2NT; 2 piece
    Ball end-mills ZCB-150 Cemented Carbide R1.5 25(l)×2.4(Lc)×65(L)×6(d)×2NT
    Ball end-mills ZCB-200 Cemented Carbide R2 25(l)×3.2(Lc)×70(L)×6(d)×2NT
    ZCB-300 Cemented Carbide R3 30(l)×4.8(Lc)×80(L)×6(d)×2NT
    Engraving cutter ZEC-100 Engraving cutters (for plastic) Cemented Carbide dia. 6×50 (L)×0.225 (W)
    Collets ZC-20-30 Collet (for end-mills), dia. 3mm
    ZC-20-32 Collet (for end-mills), dia. 3.175mm
    ZC-20-40 Collet (for end-mills), dia. 4mm
    ZC-20-60 Collet (for end-mills), dia. 6mm
    Others SM-20 Replacement spindle motor
    SS-20 Replacement spindle unit

    Reference Website Mono FAB

    Equipment we use the operation of the SRM-20

    1. A small-diameter end mill used for delicate cuts and fine details is called a 1/64 end mill.

    2. A bit bigger than the 1/64 end mill, the 1/32 end mill is perfect for engraving and precision milling.


    3. A V-shaped tool used for engraving, chamfering, and producing sharp edges is called a V bit.

    4. Collet: A clamping mechanism that keeps the end mill firmly in place within the spindle.


    5. A tool called an Allen Key (LNKEY) is used to tighten or loosen screws on tool holders and CNC machines.

    6. One kind of flame-retardant material that is frequently used to create printed circuit boards (PCBs) is called FR1 (PCB Material).

    Electronics Production

    The procedure by which manufacturers turn design ideas into functional electronic devices is known as the electronics manufacturing process in production. Design, component procurement, assembly, testing, enclosure manufacture, quality control, and packaging are just a few of the phases it includes.

    Electronics Designing Process

    For my electronic design, I am using the XIAO ESP32-C3 board because it includes WiFi and Bluetooth, which are essential for my project. Additionally, I need to integrate a display and sensors, making this board the most suitable choice for my design.

    Components Used for the PCB Device:

    To complete the design, I am using the following components:

  • 3 Resistors(1001,1001,4990 SMD)
  • 1 LED (9Green SMD)
  • 1 Switch (Omeron 5 pin SMD)
  • 3 Three-pin Connector (SMD)
  • 1 Four-pin Connector(SMD)
  • 1 XIAO ESP32-C3 Board (SMD)

    • By using the XIAO ESP32-C3 board, this design enables WiFi and Bluetooth communication, ensuring seamless integration with displays and sensors. This PCB device can be effectively used in various smart applications, including IoT, automation, and real-time monitoring.


    PCB Schematic design

    PCB Editor With Routing, And I download the Gerber file Format

    3D PCB View

    I am using Gerber2img to convert the file into a PNG format, as suggested by Neil during our Fab Academy class. "After I drag and drop my PCB Gerber file, I convert both files.

    "Download the inner PCB file in PNG format."

    "Download the outer PCB file in PNG format."

    Inner PCB Design

    Outer PCB Design
    Using Mods for G-Code Generat

    What are mods

    Users can design workflows for digital fabrication machines using Mods, an open-source, node-based, visual programming environment. Mods offers a user-friendly drag-and-drop interface for creating machine instructions in place of manually writing conventional G-code.

    Important attributes:

    Browser-Based: Operates directly in a web browser and doesn't require installation.
    Modular Workflow: Custom fabrication workflows can be created by connecting "modules" (blocks).
    Encourages Numerous Machines: Compatible with ShopBot, Roland, and further digital fabrication equipment.
    Real-Time Processing: Toolpaths are automatically updated in response to user input.

    First, I typed "https://modsproject.org/" in my browser's URL bar, and I was redirected to the dashboard.

    Open Program

    Mill 2d PCB

    After that the dashboard will always be visible

    After that I select the PNG Image

    I selected the milling bit with a 1/64-inch size.

    After this, I turned off the top button and turned on the bottom button to save the G-code file. Additionally, I set the XYZ coordinates to 000 and adjusted the jog height to 12 mm.

    Then, I clicked "Calculate" and after the process was completed, I got a G code.

    Inside file in processing

    Outside file in processing

    "G-code Toolpath Preview (1/64-inch Bit)"

    "G-code Toolpath Preview (1/32-inch Bit)"
    Using a V-panel for cutting and milling PCBs.

    The SRM-20 and other Roland CNC milling machines are officially controlled by V-Panel. It offers a user-friendly interface for regulating spindle speed, setting origins, and transmitting milling commands, among other machine functions.

    First, I set the bit (1/62).

    I opened the V-panel and moved the bit to the origin, where I could cut the PCB.

    After that, I set the Z origin.

    Then, I loosened the bit and adjusted it to match the gravity.

    After that, I set the Z origin.

    I clicked on the Cut option.

    Then, I clicked on the Add button.

    I selected the file and clicked on Output.

    The machine started running.

    The trace was successfully created on the PCB.

    Using a vacuum cleaner, I cleaned the dust from the PCB surface.

    The trace was formed properly.

    Since I needed to change the bit, I raised the Z-axis.

    I replaced the bit with a 1/32 bit.

    Only the Z origin was set again.

    I selected the Edge Cut file and clicked on Output.

    The Edge Cut process was completed.

    The PCB is now ready for soldering.

    This detailed procedure describes how I set the bit and origins, cut the traces and edge, and successfully machined a PCB. The PCB was cleaned and prepared for the soldering step after the procedure was finished.

    Soldering Process

    The method of soldering is used to create an electrical or mechanical link between metal components. Usually, a low melting point metal alloy (solder) is melted and applied to the metal components that need to be linked. When the solder hardens, it joins to the metal components and creates a connection.

    Tools are needed. A suitable surface mount solder station with a fine-tipped soldering iron, a hot air soldering tool, and ideally a set of soldering tweezers, along with a binocular microscope, are among the three-figure instruments needed for professional-level work.

    Tools
    1. Soldering Station (Temperature-controlled)
    2. Hot Air Rework Station
    3. SMD Tweezer Soldering Iron
    4. Preheater Plate
    5. Microscope or Magnifier
    6. Solder Paste Dispenser
    7. Reflow Oven
    8. Vacuum Pickup Tool
    9. ESD Mat and Wrist Strap
    10. Fume Extractor

    Components
    1. 3 Resistors(1001,1001,4990 SMD)
    2. 1 LED (9Green SMD)
    3. 1 Switch (Omeron 5 pin SMD)
    4. 3 Three-pin Connector (SMD)
    5. 1 Four-pin Connector(SMD)
    6. 1 XIAO ESP32-C3 IC

    Tools I used for soldering station

    Soldering station

    blank pcb

    I started the soldering with Subhash sir's guidance

    First I soldered the smaller components

    Then I soldered the IC and the connector. The PCB is ready for programming
    Testing the microcontroller board

    I used the Arduino IDE to test the microcontroller so that I could program my board and test the board I created.

    First, I opened Arduino IDE and selected XIAO ESP32C3 as the board. Then, I chose COM4 as the port.

    Next, I pasted the Blink Code and defined Pin 8 for the LED.

    Verified the code to check for errors.

    Uploaded the code to the board.

    Uploading...

    Uploading...

    Captured a photo of the blinking LED.

    Captured a video of the blinking LED.
    Original file is hear