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

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Introduction

Iterate

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

From ladyada on Flickr

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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

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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

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1. Concept

Electroluminescent (EL) Display Power Supply

From MAKE: Magazine 21.

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2. Prototype

Breadboarded Power Supply

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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%


3. EAGLE Schematic

Draw Symbol

The Final 10%


3. EAGLE Schematic

Draw Footprint

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3. EAGLE Schematic

Create Device

The Final 10%


3. EAGLE Schematic

Connect Pins and Pads

The Final 10%


3. EAGLE Schematic

Place Parts

The Final 10%


3. EAGLE Schematic

Draw Nets

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4. EAGLE Layout

Create Board

The Final 10%


4. EAGLE Layout

Place Parts

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4. EAGLE Layout

Route Signals

Red: Top copperBlue: Bottom copperGreen: Pads and Vias

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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

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4. EAGLE Layout

Run Design Rule Check

PCB manufacturers have limits on the minimum size andspacing of traces

The Final 10%


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

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5. CAM Processor

Verify the Gerber Files with gerbv

Make sure your gerber files were generated correctly

The Final 10%


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)

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6. Manufacturing

4PCB.com and FreeDFM.com

Deals for studentsGood for large orders

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6. Manufacturing

APCircuits.com

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

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7. The Finished PCB

Assembled EL Display Power Supply PCB

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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”

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Types of Enclosures

Off the shelf enclosures

Easy, moddable

SparkFun Adafruit

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Types of Enclosures

T-slot frames

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

The Final 10%


Types of Enclosures

Laser-cut enclosures

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

The Final 10%


Types of Enclosures

3D printed enclosures

True 3D capabilities

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Available tools

Laser cutter

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

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Available tools

3D printer

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

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Using CAD software

Start with an accurate mechanical drawing

From WayneAndLayne

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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%


Using CAD software

3D CAD

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

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Using CAD software

Tips and Tricks

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

Print out your designsCheck your units!

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Resources

Useful Resources

SparkFunAdafruitEvil Mad ScientistSolarboticsThingiversePonokoShapewaysMakerBot WikiMcMaste-Carr

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Questions

ColumbiaLaboratory for

UnconventionalElectronics

the final 10%

Self Improvement

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