elec prod fablab uae

docs/Electronics Production.md

-Electronics production
-======================
+##### Week of 17 February 2021
+#### [notes](http://academy.cba.mit.edu/classes/electronics_production/index.html) + [video](https://vimeo.com/513517157)
 
-This week I made an in-circuit programmer- the FabISP.
 
-FabISP
-------
+### THIS WEEK'S ASSIGNMENTS
+1. Group assignment: characterize the design rules for your PCB production process
+2. Individual assignment:
+-  make an in-circuit programmer that includes a microcontroller
+-  by milling and stuffing the PCB, test it,
+-  then optionally try other PCB processes
 
-### Making toolpaths
+### Objectives
+To produce a PCB using one or more manufacturing processes
+To solder components and test the board
+To program the PCB to become a programmer
 
-I downloaded the png files for the traces and the interior. I used [FabModules](http://fabmodules.org/) to create toolpaths.
+#### Introduction
+This week is about learning to fabricate a PCB, not necessarily design it. There a some different options of in-system programmers in the [FabAcademy notes](http://academy.cba.mit.edu/classes/embedded_programming/index.html#programmers). In the AVR family, there are boards based on the the ATtiny45, ATtiny44 and ATmega16U2.  
+I review all options, and decide to make the ISP based on [Brian's design](http://fab.cba.mit.edu/classes/863.16/doc/projects/ftsmin/index.html#check) because it seemed simple and straight-forward. It is called the FabTinyISP.
 
-![traces](http://academy.cba.mit.edu/classes/embedded_programming/hello.ISP.44.traces.png)
+I used the facilities in FabLab UAE to fabricate the ISP. I used the Roland SRM-20.
+![Roland SRM-20](./images/ep/rolandsrm20.jpg)  
+I use a double sided FR1 board to mill the ISP, because the lab is out of stock of single-sided ones that are not locally available.
 
-#### Traces
+An in-system programmer is basically a...
 
-The major settings for cutting traces: Input image as **.png**  
-Output file as **.rml**  
-Output file as **.rml**  
-Machine: **Roland SRM-20**  
-Speed: **3.5mm/s** as I was using a new endmill  
-Origin X,Y,Z as **0,0,0** to match the origin set in the machine locally  
-Tool diameter **1/64"**  
-Offset paths **4**, to clean area around the traces but not very time consuming  
-Overlap **50%**, Overlapping the tool paths by 50% of the tool diameter  
-Cut depth **0.1mm** to clean the top copper layer through it's thickness  
-![trace toolpath](./images/ep/toolpath.jpg)  
 
-![interior](http://academy.cba.mit.edu/classes/embedded_programming/hello.ISP.44.interior.png)
 
-#### Interior
+#### PCB fabrication Workflow
+First step is to download the design files for the traces and the outline of FabTinyISP from [Brian's documentation page](http://fab.cba.mit.edu/classes/863.16/doc/projects/ftsmin/index.html#check).
+The traces are the thin pipelines that connect the footprints of components.  
+![](http://fab.cba.mit.edu/classes/863.16/doc/projects/ftsmin/fts_mini_traces.png)  
 
-Settings for cutting the outline:
-Input image as **.png**  
-Output file as **.rml**  
-Machine: Roland **SRM-20**  
-Speed: **0.5mm/s**  
-Material depth **1.7mm**, equal to the one-sided FR1 board used  
-Cut depth **0.5mm**, cuts the outline 4 times going 0.5mm deeper with every loop  
-Origin X,Y,Z as **0,0,0** to match the origin set in the machine locally and match the traces file  
-Tool diameter **1/32"**  
-Offset paths **1**, to cut the board from the material  
+The outline is the outer boundary to be cut. Sometimes it also includes through-holes to be made in the PCBs.  
+![](http://fab.cba.mit.edu/classes/863.16/doc/projects/ftsmin/fts_mini_cut.png)
 
-### Milling the board
+It is important to note that both these images are at 1000 dpi resolution in png format.
 
-Cleaned a small piece of one-sided FR1 board with rubbing alcohol.  
-Stuck it using a double-sided tape on an MDF base we have pre-installed at the lab, that is levelled periodically.  
-Installed a 1/64" tool  
-Set the X and Y origin on the bottom left corner of the board.  
-Brought the Z really close to the top of the surface. Loosened the collet and let the bit touch the surface completely. Set the Z origin here.  
-Lifted the Z, loaded the rml traces file and start cutting. Everything seemed fine. I could see the tool cut though the copper. It took about 15 minutes to cut the whole file.  
-Later, I lifted the Z, changed the tool to the 1/32" endmill to cut the interior file. I set the Z origin again exactly as before. Keeping in mind not to change the X and Y origin. Started cutting the file. Got it done on the first try. I unattached the board using a scraper.   
-![trace toolpath](./images/ep/traces.jpg)   
-![trace toolpath](./images/ep/interior.jpg)  
+Next, these png images need to be converted to tool-paths for CNC machines to follow. [Fabmodules](http://fabmodules.org/) and [Mods](http://mods.cba.mit.edu/) both, developed by the Fab community can be used to make the tool-paths. They run in the browser.
 
-### Soldering Components
+I first use Mods.  
+![mods.traces](./images/ep/mods.traces.jpg)  
+![mods.outline](./images/ep/mods.outlines.jpg)  
 
-#### Gathering Components
+But it shows me unclear toolpaths with default settings, for both the traces and the outlines.  
+![mods.traces](./images/ep/mods.traces.error.jpg)  
+![mods.outline](./images/ep/mods.outlines.error.jpg)  
 
-Edu showed us the best way to do this was to make a shopping list, collect components and stick them on using tape. Later, we update the inventory sheet to keep count in the lab.
+I'm not sure why these errors occured. I try using FabModules with the same files and same settings. And it works perfectly. So I guess Mods has a different way to read these files.  
 
-A list of all the needed components:  
-1 x ATtiny44 (Ict44)  
-1 x 6-pin(2x3) header (J1 ISP)  
-1 x MiniUSB header (J2 USB)  
-1 x 20MHz Crystal (20MHz)  
-1 x 1uF Capacitor (C1)  
-2 x 10pF Capacitor (C2,C3)  
-2 x 3.3v Zener Diodes (D1,D2)  
-1 x 1kΩ Resistor (R1)  
-1 x 499Ω resistor (R2)  
-1 x 100Ω resistor (R3,R4)  
-1 x 10kΩ resistor (R5)  
-2 x 0Ω Resistor (SJ1, SJ2)  
-![Gathering components](./images/ep/shoppinglist.jpg)
+Thse are the steps for FabModules:
+- Select **input format: png** (same as the file downloaded)
+- Select the traces file from your directory
+- The input section on the rights shows the meta info of the image. Check the resolution is **1000 dpi** and the overall size. The - image is 1:1 so the PCB will be the same size as mentioned here.
+- Select **output format: rml** (depends on the machine you use; Roland machines use rml)
+- Select **machine** from the dropdown: **SRM-20** (I'm using this at the lab)
+- **Speed: 4 mm/s** Standard speed used with a 1/64in endmill
+- **x0, y0, z0** all **0** this makes the cutting start exactly where you set the origin on the machine
+- **zjog: 2 mm** is the distance the endmill travels in z direction when it lifts up to move in the air to another xy coordinate  
+- **xhome, yhome, zhome** are the coordinates the endmill moves to at the end of the job, i leave this empty so it take the default - value of the machine.
+- Select **process: PCB traces (1/64)** this basically fills in default values for the standard trace milling process
+- **Direction: climb** here is a diagram that explains climb vs conventional cutting
+- **Cut depth: 0.1mm** to cut through the upper layer of the FR1 boards
+- **Tool diameter: 0.4 mm** (=1/64 in)
+- **Number of offsets: 4** this is the number of paths around the traces, if its too little soldering components is difficult, if it - too much, it takes a long time to mill, 4 is just enough (-1 to remove everything completely)
+- **Offset overlap: 50%** The overlap between two paths, to ensure no material is left with error
 
-#### The solding set-up
+![fabmodules](./images/ep/fabmodules.gif)  
 
-Tools that I need to solder the components on the board: A schematic diagram that shows what components goes where.  
-![schematic](http://academy.cba.mit.edu/classes/embedded_programming/hello.ISP.44.png)  
-The components, gathered on the list. A soldering iron - I used a Weller WES51 with temperature control. Set it to 750F, not too hot, not too slow. A wet sponge, to clean the tip of the iron. Solder wire, Kester without a flux co. A anti-static curved tweezer to place down components accurately. A copper braid for desoldering excess solder. A table-top light, a silicon base to hold the board stationary, and a fan to remove fumes.
+With these settings, I **calculate** the toolpaths for the traces and **save** the rml file.  
+Making the outline has the same process except the following changes:
+2. Select the outline file from your directory
+10. Select **process: PCB outline (1/32)** because outline is milled with a different endmill
+12. **Cut depth: 0.6mm** keep this a bit smaller than the tool diameter, so it doesn't break the bit
+13. **Tool diameter: 0.8 mm** (=1/32 in)
+14. **Stock thickness: 1.7 mm** Thickness of the FR1 stock measured with a calliper
+15. **Number of offsets: 1** The outline can be cut with just 1 path around the board
 
-#### Soldering order
+Since the cut depth is 0.6, to  cut through the 1.7 mm stock, it will run the path 3 times till it cuts through the entire thickness of the stock.  This can be seen when you **calculate** the toolpath.
 
-I started from the complex to the simple, then top to bottom. I soldered the microcontroller first, matched the orientation from from the data sheet. Second, I soldered the MiniUSB, since, it had very tiny trace connections. The zener diodes, have polarities. i soldered them next. Oscar taught me how the way to remember their direction, the electric symbol has a line that corresponds to the Cathode. Similarly, the component is marked with a line in its cathode side. Polarity symbol The rest of the components don't have any polarities, so I soldered them from top to bottom inside-out in this order: R1>R2>R3>R4>SJ2>20MHz>C2>C3>SJ1>R5>C1 and the J1 header in the end, because it had comparatively larger feet.
+![outline.toolpath](./images/ep/toolpath.outline.jpg)
 
-#### Checking connections
+After saving the toolpaths, next step is to prep the machine for milling.
+On the left bottom corner, fix the FR1 board with a double-sided adhesive tape.  
 
-I visually checked the board under a lens to check no traces or solders touched each other. Then using a multimeter setting with no resistance, I connected all pin legs to where the traces connected using the schematic diagram. And checked that all beeped, suggesting there was no short. I cleaned the board again, using some rubbing alcohol. This is how my finished board looks: ![Soldering components](./images/ep/finished.jpg)
+SRM-20 can be controlled with a V-panel.
+![v-panel](./images/ep/vpanel.PNG)
 
-#### Testing the board
-
-[steps](http://archive.fabacademy.org/archives/2017/fablabverket/students/100/web/assignments/week4/index.html#programming) [or these](http://archive.fabacademy.org/archives/2017/fablabverket/students/100/web/assignments/week4/index.html#programming)
+  

docs/Electronics Production2020.md

+Electronics production
+======================
+
+This week I made an in-circuit programmer- the FabISP.
+
+FabISP
+------
+
+### Making toolpaths
+
+I downloaded the png files for the traces and the interior. I used [FabModules](http://fabmodules.org/) to create toolpaths.
+
+![traces](http://academy.cba.mit.edu/classes/embedded_programming/hello.ISP.44.traces.png)
+
+#### Traces
+
+The major settings for cutting traces: Input image as **.png**  
+Output file as **.rml**  
+Output file as **.rml**  
+Machine: **Roland SRM-20**  
+Speed: **3.5mm/s** as I was using a new endmill  
+Origin X,Y,Z as **0,0,0** to match the origin set in the machine locally  
+Tool diameter **1/64"**  
+Offset paths **4**, to clean area around the traces but not very time consuming  
+Overlap **50%**, Overlapping the tool paths by 50% of the tool diameter  
+Cut depth **0.1mm** to clean the top copper layer through it's thickness  
+![trace toolpath](./images/ep/toolpath.jpg)  
+
+![interior](http://academy.cba.mit.edu/classes/embedded_programming/hello.ISP.44.interior.png)
+
+#### Interior
+
+Settings for cutting the outline:
+Input image as **.png**  
+Output file as **.rml**  
+Machine: Roland **SRM-20**  
+Speed: **0.5mm/s**  
+Material depth **1.7mm**, equal to the one-sided FR1 board used  
+Cut depth **0.5mm**, cuts the outline 4 times going 0.5mm deeper with every loop  
+Origin X,Y,Z as **0,0,0** to match the origin set in the machine locally and match the traces file  
+Tool diameter **1/32"**  
+Offset paths **1**, to cut the board from the material  
+
+### Milling the board
+
+Cleaned a small piece of one-sided FR1 board with rubbing alcohol.  
+Stuck it using a double-sided tape on an MDF base we have pre-installed at the lab, that is levelled periodically.  
+Installed a 1/64" tool  
+Set the X and Y origin on the bottom left corner of the board.  
+Brought the Z really close to the top of the surface. Loosened the collet and let the bit touch the surface completely. Set the Z origin here.  
+Lifted the Z, loaded the rml traces file and start cutting. Everything seemed fine. I could see the tool cut though the copper. It took about 15 minutes to cut the whole file.  
+Later, I lifted the Z, changed the tool to the 1/32" endmill to cut the interior file. I set the Z origin again exactly as before. Keeping in mind not to change the X and Y origin. Started cutting the file. Got it done on the first try. I unattached the board using a scraper.   
+![trace toolpath](./images/ep/traces.jpg)   
+![trace toolpath](./images/ep/interior.jpg)  
+
+### Soldering Components
+
+#### Gathering Components
+
+Edu showed us the best way to do this was to make a shopping list, collect components and stick them on using tape. Later, we update the inventory sheet to keep count in the lab.
+
+A list of all the needed components:  
+1 x ATtiny44 (Ict44)  
+1 x 6-pin(2x3) header (J1 ISP)  
+1 x MiniUSB header (J2 USB)  
+1 x 20MHz Crystal (20MHz)  
+1 x 1uF Capacitor (C1)  
+2 x 10pF Capacitor (C2,C3)  
+2 x 3.3v Zener Diodes (D1,D2)  
+1 x 1kΩ Resistor (R1)  
+1 x 499Ω resistor (R2)  
+1 x 100Ω resistor (R3,R4)  
+1 x 10kΩ resistor (R5)  
+2 x 0Ω Resistor (SJ1, SJ2)  
+![Gathering components](./images/ep/shoppinglist.jpg)
+
+#### The solding set-up
+
+Tools that I need to solder the components on the board: A schematic diagram that shows what components goes where.  
+![schematic](http://academy.cba.mit.edu/classes/embedded_programming/hello.ISP.44.png)  
+The components, gathered on the list. A soldering iron - I used a Weller WES51 with temperature control. Set it to 750F, not too hot, not too slow. A wet sponge, to clean the tip of the iron. Solder wire, Kester without a flux co. A anti-static curved tweezer to place down components accurately. A copper braid for desoldering excess solder. A table-top light, a silicon base to hold the board stationary, and a fan to remove fumes.
+
+#### Soldering order
+
+I started from the complex to the simple, then top to bottom. I soldered the microcontroller first, matched the orientation from from the data sheet. Second, I soldered the MiniUSB, since, it had very tiny trace connections. The zener diodes, have polarities. i soldered them next. Oscar taught me how the way to remember their direction, the electric symbol has a line that corresponds to the Cathode. Similarly, the component is marked with a line in its cathode side. Polarity symbol The rest of the components don't have any polarities, so I soldered them from top to bottom inside-out in this order: R1>R2>R3>R4>SJ2>20MHz>C2>C3>SJ1>R5>C1 and the J1 header in the end, because it had comparatively larger feet.
+
+#### Checking connections
+
+I visually checked the board under a lens to check no traces or solders touched each other. Then using a multimeter setting with no resistance, I connected all pin legs to where the traces connected using the schematic diagram. And checked that all beeped, suggesting there was no short. I cleaned the board again, using some rubbing alcohol. This is how my finished board looks: ![Soldering components](./images/ep/finished.jpg)
+
+#### Testing the board
+
+[steps](http://archive.fabacademy.org/archives/2017/fablabverket/students/100/web/assignments/week4/index.html#programming) [or these](http://archive.fabacademy.org/archives/2017/fablabverket/students/100/web/assignments/week4/index.html#programming)