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Week08 Electronics Production

Overview

This week focuses on Electronics Production, where we learn how to fabricate printed circuit boards (PCBs) using in-house machines and processes. The goal is to understand the PCB manufacturing workflow, including preparing design files, producing the board, soldering components, and testing the circuit.

This week connects electronics design skills from previous weeks with physical production, enabling us to transform digital PCB designs into functional electronic systems using the BotFactory SV2 additive inkjet PCB printer.

“The bridge between circuit design and real-world hardware—where ideas become tangible.”

Learning Objectives

Objective Description
PCB Fabrication Workflow Understand complete process from design to tested hardware
Design Rules Characterize limitations of in-house PCB production
Additive Manufacturing Learn inkjet PCB printing with BotFactory SV2
Component Assembly Solder and assemble SMD components including ESP32-C3
Programming & Testing Upload firmware and verify system functionality
Process Characterization Document trace width, clearance, and conductivity results

Group Assignment … on progress

Group assignment for week08

Individual Assignment … on progress

Make and Test an Embedded Microcontroller System

Assignment Objective

Manufacture and test an embedded microcontroller system that I designed previously, using the characterized design rules from the group assignment. The board is based on the Seeed Studio XIAO ESP32-C3 module.

Task Breakdown

Phase Task Status Documentation
1. Design Prepare PCB in KiCad with XIAO ESP32-C3 Complete Design Files
2. Export Generate Gerbers with correct design rules Complete Manufacturing Files
3. Print Fabricate using BotFactory SV2 Complete Printing Process
4. Inspect Verify traces and measure resistance Complete Inspection
5. Assemble Solder components including XIAO Complete Assembly
6. Program Upload firmware to ESP32-C3 Complete Programming
7. Test Verify all functions work Complete Testing & Verification
8. Document Complete documentation with images Complete This page

Part 1: PCB Design & Preparation

Schematic Design

The embedded system is built around the Seeed Studio XIAO ESP32-C3, a compact WiFi/Bluetooth module with rich I/O capabilities and printed but XIAO C3 Currently unavailable in the center stock (soon I install it on my printed board), my Local Instructor Rico gave me the permission to use temporarily the (ESP32-WROOM-32D): This is a standard module made by Espressif. It contains the MCU chip, memory, and antenna circuitry, designed to be soldered onto a larger circuit board, but too many pins than XIAO’S.

Key Components: - XIAO ESP32-C3 main module or ESP32-WROOM-32D - LED indicators with resistors (3x) - Push button input - I2C connector/header - UART connector - Analog pin connector - Digital pin connector - Programming header - Power connections (5V and GND pins)

XIAO ESP-C3 PCB schematic for PCB process

PCB Layout

Design rules applied (from group assignment):

Parameter Applied Value
Trace Width 12 mil
Clearance 12 mil
Pad Size 1.2 mm
Via Size 0.8 mm

PCB layout with XIAO ESP32-C3 footprint alt text

Design Rule Check (DRC)

KiCad DRC Results: - Violations: 0 - Unconnected items: 0 - Clearance violations: 0 - Track width violations: 0 - Status: PASS More about the design of the electronics found on the week06 page. week06 page

Part 2: Printing Process

The circuit board process to made the electronics PCB was done using the Botfactory SV2P. https://www.botfactory.co/

BotFactory SV2P Desktop PCB Printer

The BotFactory SV2+ is a next-generation all-in-one desktop printer designed to revolutionize PCB prototyping by enabling engineers to fabricate and assemble functional circuit boards directly from their desk in a matter of hours, eliminating the weeks-long wait times and IP risks associated with traditional outsourcing. Its core purpose is to condense an entire PCB lab into a single bench-top unit, allowing for rapid iteration and development of multi-layer circuits on various substrates without external dependencies. The machine achieves this through a series of automated, swappable heads that print conductive and insulating inks, dispense solder paste, place components, and reflow the board all in one seamless workflow.

  • Integrated Functionality: Combines a conductive ink inkjet printer, solder paste extruder, pick-and-place machine, and a heated reflow bed into a single desktop device.
  • Software Interface: Controlled via a browser-based software that resides on the machine itself, requiring no internet connection for operation, though an internet connection is needed for software updates.
  • Multi-Layer & Flexible Printing: Capable of printing 4-layer PCBs and supports a variety of rigid and flexible substrates including FR-4, Kapton, glass, and fabric.
  • Printing Capabilities: Can print traces as small as 8 mil (0.2 mm) and adjust layer thickness in roughly 5-micrometer increments to help manage impedance.
  • Component Placement: Equipped with a vision system to pick and place surface-mount devices (SMDs) presented on tape or in multi-compartment trays, handling components down to 0603 size and 0.4mm pitch.
  • Essential Consumables: Requires specialized consumables for operation, including silver nanoparticle conductive ink, UV-curable insulating ink, and low-temperature solder paste or conductive glue.
  • Key Output: Designed to produce a fully assembled, functional printed circuit board ready for testing and debugging, significantly accelerating the prototyping process for R&D labs, academic research, and home-based engineers.

BotFactory SV2P Desktop PCB Printer alt text More

SV2 PCB Printer – Step-by-Step Operation Guide

Overview

As described above the SV2 PCB printer is a desktop rapid-prototyping machine that prints conductive traces directly onto a PCB substrate using conductive ink. It enables fast PCB prototyping without traditional etching or milling.

The printer is controlled through a web-based interface and can print traces using silver or copper conductive ink on materials such as FR4 boards or flexible substrates.

1. Power On the Printer

Turn on the SV2 PCB printer using the main power switch located on the back of the machine.

Description

When powered on:

  • The internal controller initializes.
  • The printhead moves to its home position.
  • The system performs a quick hardware check.

Allow 1–2 minutes for the machine to fully initialize before starting operations.

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2. Connect to the SV2 Web Interface

The printer is operated through a browser-based interface.

Steps

  1. Connect your computer to the same network as the printer.
  2. Open a web browser.
  3. Enter the printer IP address in the address bar.
  4. WiFi, USB and RJ45 LAN connection options are there

Example:

[http://10.10.10.10](http://10.10.10.10)
  • Google Chrome
  • Mozilla Firefox

Description

The web interface allows you to:

  • Upload PCB design files
  • Run calibration routines
  • Control printing operations
  • Monitor system status

alt text

3. Prepare the PCB Substrate

Choose the material that will be used for printing.

Common Substrates

  • FR4 PCB board
  • Polyimide film
  • Flexible PCB substrate
  • Glass or plastic sheets (experimental)

Preparation Steps

  1. Clean the substrate using isopropyl alcohol (IPA).
  2. Remove dust, grease, or debris.
  3. Ensure the surface is flat and completely dry.

Description

A properly cleaned substrate improves:

  • Ink adhesion
  • Trace quality
  • Electrical conductivity

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4. Load the Substrate into the Printer

Place the prepared substrate onto the printer bed.

Steps

  1. Open the printer cover.
  2. Place the FR4 board on the printing platform.
  3. Align the board with the reference markers.
  4. Secure the substrate using the vacuum bed or clamps.

Description

Correct positioning ensures accurate trace printing and prevents misalignment during the printing process.

sv2 ready with substrate

5. Install the Conductive Ink Cartridge

Insert the conductive ink cartridge into the printhead.

Ink Types

  • Silver conductive ink
  • Copper conductive ink

Steps

  1. Remove the protective cap from the ink cartridge.
  2. Insert the cartridge into the printhead holder.
  3. Lock the cartridge in place.
  4. Confirm cartridge detection in the printer interface.

Description

The conductive ink is responsible for forming the electrical traces of the PCB.

Proper installation ensures:

  • Stable ink flow
  • Consistent trace width

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6. Run the Nozzle Test

Before printing, verify that the printhead nozzles are working properly.

Steps

  1. Open the Maintenance tab in the interface.
  2. Select Nozzle Test.
  3. Start the test print.

Description

The printer will print a test pattern used to check:

  • Ink flow
  • Nozzle blockage
  • Printing consistency

If the test shows missing lines or irregular patterns, perform a printhead cleaning cycle.

7. Perform Printhead Calibration

Calibration ensures the printhead is aligned correctly with the substrate.

Steps

  1. Open the Calibration menu.
  2. Run the printhead alignment routine.
  3. Adjust settings if needed.

Description

Calibration corrects:

  • Mechanical alignment errors
  • Printhead offset
  • Positioning inaccuracies

Print head calibration alt text

8. Upload the PCB Design File

Upload the PCB layout file to the printer.

Supported File Formats

  • Gerber files
  • SVG files
  • Compatible SV2 design formats

Steps

  1. Click Upload Design.
  2. Select the PCB file from your computer.
  3. Confirm the upload.

Description

The design file contains:

  • Copper trace layout
  • Component pads
  • PCB board outline

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9. Configure Printing Parameters

Adjust printing settings before starting the print job.

Key Parameters

Parameter Description
Ink Flow Rate Controls how much ink is deposited
Print Speed Determines movement speed of printhead
Trace Thickness Adjusts electrical conductivity
Layer Count Number of printed layers

Description

Proper parameter configuration improves the overall quality and reliability of the printed PCB.

10. Start the PCB Printing Process

Begin printing the PCB.

Steps

  1. Click Start Print.
  2. Monitor the printing process through the web interface.

Description

During printing:

  • The printhead deposits conductive ink onto the substrate.
  • The machine follows the PCB layout path.
  • Traces are formed layer by layer.

PCB Printing process PCB Printing process

11. Cure the Printed PCB

After printing, the conductive ink must be cured.

Methods

  • Built-in curing system
  • External oven
  • UV curing (depending on ink type)

Typical Temperature

120°C – 150°C

Description

Curing strengthens the conductive traces and improves electrical performance.

Curred final PCB with XAIO ESP32-C3 pins alt text

12. Inspect the Printed PCB

After curing, inspect the printed board carefully.

Inspection Checklist

  • Verify trace continuity
  • Check trace thickness
  • Look for broken or incomplete traces (too much times breaking)
  • Test connectivity using a multimeter

Description

This step ensures the PCB is ready for component assembly and soldering.

alt text

13. Remove the PCB and Clean the Printer

After completing the print job:

Steps

  1. Carefully remove the PCB from the printer bed.
  2. Clean excess ink from the printing area.
  3. Seal the ink cartridge properly.
  4. Turn off the printer if no further jobs are planned.

Description

Cleaning helps maintain the printer and prevents ink from drying inside the printhead.

Generally:

The is designed to Print, PNP and pasting of the PCB designs, SV2 PCB printing workflow consists of the following major stages: 1. Power on and system initialization (some times I see it needs remove heads switch off all source then power on) 2. Connect to the printer interface
3. Prepare and load the substrate
4. Install conductive ink cartridge , shake well 5. Run nozzle test and calibration
6. Upload PCB design, follow on screen guidelines
7. Configure print settings
8. Print PCB traces
9. Cure conductive ink
10. Inspect and clean the printer

Following these steps ensures high-quality PCB prototypes with reliable conductive traces.

Problem faced during SV2 Botfactory usage for PCB printer

Soldering being done hardly progress

The SV2 botfactory really print PCB but paste and soldering spot most be completed in the process, paste is not done in my case. Tested the circuit, working.... alt text

The soldering @ 300 to 350 disconnect the circuit printed due to fading from FR4 alt text

Test for continuity …

Conclusion

Hard to soldering on SV2 Printed circuit due to discontinuity on the lines by high soldering temperature

The PCB tracing and milling process then followed this step to solder the XIAO ESP C3, Additional, I want to design in different method for the PCB board part Using modsproject.org

I used modsprojec.org to export my .svg to made the PCB board from FR4 Copper but first check on mdf

  • I got to modsproject.org did my import and setup
  • I open project and import svg (step given in the below picture 1)

  • alt text

  • I selecting folder for the machine … in my case G code 2d PCB milling

  • I follow on screen command and fill my v bit drill and 1000dpi
  • I do the option invert in modsprojects
  • to save turn on the savebutton or off to see the 3D
  • I send to the Mach3 as .cn file and cutting the PCB

alt text

First I tried with wood 3mm mdf

alt text

Correct the modsproject exporting methods

  • dpi- 1000
  • invert to trace the copper part as circuit lines and 1/64’’ selected
  • correct my vbit (60) alt text
  • and open Mach3 then import the .cn from pc

alt text - Trace with and test for continuity

alt text

  • Tested and a bit correction needed at two circuit lines

pcb tested

…

XIAO… waited

Youtube PCB on MDF

Desgned File

ESP32 Dkit PCB board

ESP32

My PCB works

Reference