The Final 10%
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The Final 10%
The Final 10%
John Sarik
Columbia UniversityDepartment of Electrical Engineering
Columbia Laboratory for Unconventional Electronics
April 5, 2011
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The Final 10%
Introduction
Hardware Design Flow
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The Final 10%
Introduction
What is “The Final 10%”?
The extra effort at the end of a projectTransforms projects from “functional” to “amazing”
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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.
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The Final 10%
Introduction
Design - Picking Parts
Distributors (Digikey, Mouser, Newark, etc) have largeselections, but can be hard to search
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The Final 10%
Introduction
Design - Picking Parts
Manufacturers provide application notes, example circuits,and free samples
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The Final 10%
Introduction
Build - Connecting Parts
BreadboardPerfboardPrinted Circuit Board
From oomlut on Flickr From Revolt Labs on Instructables From ladyada on Flickr
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The Final 10%
Introduction
Test - Characterizing Circuits
Does my circuit do what I want it do?
From Wikimedia Commons
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The Final 10%
Introduction
Iterate
“The design process is part intuition, part art and alliterative tenacity” -Amanda Wozniak
From ladyada on Flickr
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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
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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
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The Final 10%
Designing a printed circuit board
1. Concept
Electroluminescent (EL) Display Power Supply
From MAKE: Magazine 21.
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The Final 10%
Designing a printed circuit board
2. Prototype
Breadboarded Power Supply
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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.
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The Final 10%
Designing a printed circuit board
3. EAGLE Schematic
Draw Symbol
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The Final 10%
Designing a printed circuit board
3. EAGLE Schematic
Draw Footprint
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The Final 10%
Designing a printed circuit board
3. EAGLE Schematic
Create Device
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The Final 10%
Designing a printed circuit board
3. EAGLE Schematic
Connect Pins and Pads
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The Final 10%
Designing a printed circuit board
3. EAGLE Schematic
Place Parts
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The Final 10%
Designing a printed circuit board
3. EAGLE Schematic
Draw Nets
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The Final 10%
Designing a printed circuit board
4. EAGLE Layout
Create Board
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The Final 10%
Designing a printed circuit board
4. EAGLE Layout
Place Parts
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The Final 10%
Designing a printed circuit board
4. EAGLE Layout
Route Signals
Red: Top copperBlue: Bottom copperGreen: Pads and Vias
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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
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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
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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
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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
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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)
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The Final 10%
Designing a printed circuit board
6. Manufacturing
4PCB.com and FreeDFM.com
Deals for studentsGood for large orders
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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
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The Final 10%
Designing a printed circuit board
7. The Finished PCB
Assembled EL Display Power Supply PCB
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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!
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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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The Final 10%
Designing an enclosure
Types of Enclosures
Off the shelf enclosures
Easy, moddable
SparkFun Adafruit
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The Final 10%
Designing an enclosure
Types of Enclosures
T-slot frames
Large scale: 80/20Small scale: Makerbeam, Microrax
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The Final 10%
Designing an enclosure
Types of Enclosures
Laser-cut enclosures
2D Acrylic + 4-40 Screws & Nuts = 3D Enclosure
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The Final 10%
Designing an enclosure
Types of Enclosures
3D printed enclosures
True 3D capabilities
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The Final 10%
Designing an enclosure
Available tools
Laser cutter
Universal VLS3.5012" x 24" bed, 40W CO2 laserRequires DXF (Drawing Interchange File)
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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
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The Final 10%
Designing an enclosure
Using CAD software
Start with an accurate mechanical drawing
From WayneAndLayne
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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
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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”
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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!
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The Final 10%
Resources
Useful Resources
SparkFunAdafruitEvil Mad ScientistSolarboticsThingiversePonokoShapewaysMakerBot WikiMcMaste-Carr
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The Final 10%
Questions
ColumbiaLaboratory for
UnconventionalElectronics