the final 10%

The Final 10%

The Final 10%

John Sarik

Columbia UniversityDepartment of Electrical Engineering

Columbia Laboratory for Unconventional Electronics

April 5, 2011

The Final 10%

Introduction

Hardware Design Flow

The Final 10%

Introduction

What is “The Final 10%”?

The extra effort at the end of a projectTransforms projects from “functional” to “amazing”

The Final 10%

Introduction

What is the other 90%?

A functional prototype

Intel 8088-based single board computer constructed on a breadboard. From Wikimedia Commons.

The Final 10%

Introduction

Design - Picking Parts

Distributors (Digikey, Mouser, Newark, etc) have largeselections, but can be hard to search

The Final 10%

Introduction

Design - Picking Parts

Manufacturers provide application notes, example circuits,and free samples

The Final 10%

Introduction

Build - Connecting Parts

BreadboardPerfboardPrinted Circuit Board

From oomlut on Flickr From Revolt Labs on Instructables From ladyada on Flickr

The Final 10%

Introduction

Test - Characterizing Circuits

Does my circuit do what I want it do?

From Wikimedia Commons

The Final 10%

Introduction

Iterate

“The design process is part intuition, part art and alliterative tenacity” -Amanda Wozniak

From ladyada on Flickr

The Final 10%

Designing a printed circuit board

What’s in a PCB?

Parts consist of a symbol and a footprintSchematic

Shows connections between part symbolsUsed to generate a “netlist” for a board

BoardShows physical connections between part footprintsThese connections are copper traces that must be routedaccording to a set of design rulesUsed to generate “gerber files” for a board house

The Final 10%

Designing a printed circuit board

What is EAGLE?

Easily Applicable Graphical Layout Editor (EAGLE)Computer Aided Design (CAD) Software for Printed CircuitBoard (PCB) Design

Crossplatform (Windows, Mac, Linux)EAGLE Light is free for non-profit applications

Four Main ComponentsSchematic EditorLayout EditorAutorouterCAM Processor

The Final 10%

Designing a printed circuit board

1. Concept

Electroluminescent (EL) Display Power Supply

From MAKE: Magazine 21.

The Final 10%

Designing a printed circuit board

2. Prototype

Breadboarded Power Supply

The Final 10%

Designing a printed circuit board

3. EAGLE Schematic

Create Parts

EAGLE includes libraries with commonly used parts3rd party libraries add even more partsBut sometimes you may have to create your own parts

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Specifications are subject to change without notice. No liability or warranty implied by this information. Environmental compliance based on producer documentation.

The Final 10%

Designing a printed circuit board

3. EAGLE Schematic

Draw Symbol

The Final 10%

Designing a printed circuit board

3. EAGLE Schematic

Draw Footprint

The Final 10%

Designing a printed circuit board

3. EAGLE Schematic

Create Device

The Final 10%

Designing a printed circuit board

3. EAGLE Schematic

Connect Pins and Pads

The Final 10%

Designing a printed circuit board

3. EAGLE Schematic

Place Parts

The Final 10%

Designing a printed circuit board

3. EAGLE Schematic

Draw Nets

The Final 10%

Designing a printed circuit board

4. EAGLE Layout

Create Board

The Final 10%

Designing a printed circuit board

4. EAGLE Layout

Place Parts

The Final 10%

Designing a printed circuit board

4. EAGLE Layout

Route Signals

Red: Top copperBlue: Bottom copperGreen: Pads and Vias

The Final 10%

Designing a printed circuit board

4. EAGLE Layout

Routing Tips

Routing by hand is preferable, but not always possiblePart placement is crucialEAGLE’s Autorouter is good enough for simple boardsFreerouting.net has an excellent, EAGLE-compatibleautorouter for more complex boards

The Final 10%

Designing a printed circuit board

4. EAGLE Layout

Run Design Rule Check

PCB manufacturers have limits on the minimum size andspacing of traces

The Final 10%

Designing a printed circuit board

5. CAM Processor

Generate Gerber and Drill Files

EAGLE uses CAM files to generate gerber filesBoard houses use these gerber files to make your PCB

The Final 10%

Designing a printed circuit board

5. CAM Processor

Verify the Gerber Files with gerbv

Make sure your gerber files were generated correctly

The Final 10%

Designing a printed circuit board

6. Manufacturing

Gerber and Drill Files to Submit

Layers RequiredOutlineDrill fileTop copperBottom copper

Optional LayersTop and bottom stencil (labels)Top and bottom solder mask (protective coating)

The Final 10%

Designing a printed circuit board

6. Manufacturing

4PCB.com and FreeDFM.com

Deals for studentsGood for large orders

The Final 10%

Designing a printed circuit board

6. Manufacturing

APCircuits.com

Reasonable prices for quick turn boards2-day turn around, but no soldermask or stencils

The Final 10%

Designing a printed circuit board

7. The Finished PCB

Assembled EL Display Power Supply PCB

The Final 10%

Designing a printed circuit board

7. The Finished PCB

Tips and Tricks

Harness the power of open-source hardware!Label EVERYTHING!Triple check EVERYTHING!

Print out custom part layoutsPrint out final board designs

Avoid the classic Arduino spacing error!

The Final 10%

Designing an enclosure

Why do you need an enclosure?

Enhances your project’s “wow factor”Provides protection from the “negation fields”

The Final 10%

Designing an enclosure

Types of Enclosures

Off the shelf enclosures

Easy, moddable

SparkFun Adafruit

The Final 10%

Designing an enclosure

Types of Enclosures

T-slot frames

Large scale: 80/20Small scale: Makerbeam, Microrax

The Final 10%

Designing an enclosure

Types of Enclosures

Laser-cut enclosures

2D Acrylic + 4-40 Screws & Nuts = 3D Enclosure

The Final 10%

Designing an enclosure

Types of Enclosures

3D printed enclosures

True 3D capabilities

The Final 10%

Designing an enclosure

Available tools

Laser cutter

Universal VLS3.5012" x 24" bed, 40W CO2 laserRequires DXF (Drawing Interchange File)

The Final 10%

Designing an enclosure

Available tools

3D printer

Dimension uPrint Plus8" x 8" x 6" build areaRecommended 0.075" minimum feature sizeRequires STL (Stereolithography) file

The Final 10%

Designing an enclosure

Using CAD software

Start with an accurate mechanical drawing

From WayneAndLayne

The Final 10%

Designing an enclosure

Using CAD software

2D CAD

Can use any software that generates vector images(AutoCAD, Illustrator, etc)Inkscape is free and (relatively) easyExporting between different file formats can be frustrating

The Final 10%

Designing an enclosure

Using CAD software

3D CAD

Can use any software that generates STL files (AutoCAD,SolidWorks, SketchUp, etc)OpenSCAD is “The Programmers Solid 3D CAD”

The Final 10%

Designing an enclosure

Using CAD software

Tips and Tricks

Harness the power of open-source hardware!Measure EVERYTHING!Triple check EVERYTHING!

Print out your designsCheck your units!

The Final 10%

Resources

Useful Resources

SparkFunAdafruitEvil Mad ScientistSolarboticsThingiversePonokoShapewaysMakerBot WikiMcMaste-Carr

The Final 10%

Questions

ColumbiaLaboratory for

UnconventionalElectronics