Final Project Development

Your project should incorporate 2D and 3D design:

additive and subtractive fabrication processes,
electronics design and production,
embedded microcontroller design, interfacing, and programming,
system integration and packaging

Where possible, you should make rather than buy the parts of your project

Projects can be separate or joint, but need to show individual mastery of the skills, and be independently operable

PCB Design and Production

Learning : Always keep XIAO connection on top layer.

Learning : Always keep through hole connection for module either on top or on bottom any one layer. so this will avoid vias at the pin-header connection.

do not keep vias underneath od XIAO

When using magnetometer do not keep any copper high current traces underneath, remove all copper clade from beneath it.

Schematics

PCB Layout

PCB Render

Encloser Design

Enclosure

Embroidery Pixel Module

I decided to make Embroidery pixel module in the lab and then use it in the embroidery work. To do this, my instructor suggested to use Carvera PCB Machine because I can multiply the modules in the gerber to PNG layout and then mass-produce it with less wastage.

Digital Fabrication Process : KiCAD PCB Design --> Gerber to PNG (Layout for 40 Modules)--> Mods CE (Generate G-Code) --> Carvera Controller --> PCB Milling --> Soldering --> Testing on Jig --> Done!

KiCad PCB Design

First, I made the schematic design with WS2812B and used 0.1 uF capacitor across the positive and negative act as local energy storage.

Schematics

Pad Shape Modification

3D Embroidery Pixel Module

Embroidery Pixel Module

Testing Setup

Gerber to PNG (Layout for 40 Modules)

I used Layout option in Gerber2PNG to generate Layout for milling 40 Modules. As si was going to use Carvera Machine, I selected Generate for Carvera and then in Layout Setup, I entered 5 rows and 8 columns and downloaded the PNG. This steps need to be done for both TraceLayer and DrillLayer.

Trace Layer

Drill Layer

Mods CE (Generate G-COde)

Now, we need to open these PNG files of TraceLayer and DrillLayer into ModsCE to generate the G-code/Tool path for Carvera Machine.

When we start mods and load Carvera the default values are different . But after opening mods and clicking " load file " from the left side bar I added below file which will setup the defaults values that fits our machine, so that's e don't have to change it every time. CarveraMODSSV4.4.json

ModsCE - ToolPath Generation

We can verify the Tool path using online NC Viewer or also in CARVERA CONTROLLER Software.

Online NC Viewer - ToolPath Verification

Carvera Controller

Carvera Controller Tool that we can install and use to connect with Carvera Machine wirelessly via wifi. The tool can be downloaded for here --> Carvera & Carvera Air Controller.

Carvera Controller

Below is its home screen and follow below Steps for setup.

Step 1: Connect to wifi by clicking on "NA" button
Step 2: Click "None" button and Select "Prob" : the machine will begin do Automatic calibration.
Step 3: Click "Side Aero" button, a new screen will slide from the right, set the job origin using x+/x- and y+/y- buttons.
Step 3: Click "Side Aero" button, a new screen will slide from the right, set the job origin using x+/x- and y+/y- buttons.
Step 4: Click "Set Origin" Enter X-offset:0 and Y-offset:0, select "current pos"
Step 5: Click "Config and Run" select Auto leveling enter x-points and y-points.
Step 6: Click "Open" in the left bottom and open the G-code file.
Step 7: Click "Upload & Select" and then "Run"