Jeff Moe
4 years ago
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25b6c043cc
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#Summary
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- [PCBA](#section-id-1)
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- [Prototype PCBA Manufacturing](#section-id-5)
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- [Software](#section-id-12)
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- [Debian](#section-id-16)
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- [Other Software](#section-id-50)
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- [Electronic Design Automation (EDA)](#section-id-69)
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- [PCB Manufacturing](#section-id-73)
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- [Board Types and Features](#section-id-85)
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- [Copper Layer](#section-id-88)
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- [Soldermask](#section-id-91)
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- [Silkscreen](#section-id-94)
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- [Standards & QC](#section-id-97)
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- [PCB Assembly](#section-id-104)
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- [Placement](#section-id-115)
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- [Solder Paste](#section-id-130)
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- [Solder Wire](#section-id-139)
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- [Flux](#section-id-146)
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- [Flux Remover](#section-id-151)
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- [Low Melt Alloy](#section-id-158)
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- [Solder Wick](#section-id-163)
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- [Heat](#section-id-168)
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- [PCBA Processes](#section-id-181)
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- [Solder through hole components with soldering iron](#section-id-184)
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- [Solder SMT components with soldering iron](#section-id-187)
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- [Solder SMT components with hot air](#section-id-190)
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- [Solder SMT components with oven](#section-id-193)
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- [Solder SMT components with skillet](#section-id-196)
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- [Solder BGA components](#section-id-199)
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- [Rework through hole components](#section-id-202)
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- [Rework SMT components](#section-id-210)
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- [Rework BGA components](#section-id-218)
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- [Create solder paste stencil](#section-id-221)
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- [Apply solder paste with solder paste mask](#section-id-229)
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- [Apply solder paste with syringe](#section-id-232)
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- [Apply solder paste with electronic syringe](#section-id-235)
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- [Solder Pot](#section-id-238)
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- [PCBA Testing](#section-id-244)
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- [Equipment](#section-id-247)
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- [LASER](#section-id-252)
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- [CNC](#section-id-263)
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- [3D Printer](#section-id-273)
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- [Solder Station](#section-id-283)
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- [Pick and Place](#section-id-310)
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- [Production Boards](#section-id-320)
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- [Copying / License](#section-id-329)
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<div id='section-id-1'/>
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# PCBA
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PCB Assembly. Soldering. SMT. Thru hole. Stencils. Paste. Equipment. Tools. HOWTOs.
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<div id='section-id-5'/>
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# Prototype PCBA Manufacturing
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This documents free software and open source hardware manufacturing
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of PCBAs (Printed Circuit Board Assemblies).
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Focus is particularly on tools that can be used with hackerspace-
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level technology.
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<div id='section-id-12'/>
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# Software
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Various Free Software (as defined by FSF) applications available
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for the creation of PCBAs.
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<div id='section-id-16'/>
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## Debian
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The below packages are in Debian Buster. Note, even though it is in
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Debian, you may want to build some of these packages from scratch
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since the version in Debian is old. Debian `backports` maintains
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an up to date KiCAD.
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The following Debian packages are in use in the current production toolchain:
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* `freecad` --- Visualization of PCBAs and more. 3D CAD application.
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* `inkscape` --- vector-based drawing program.
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* `kicad` --- Electronic schematic and PCB design software.
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The following Debian packages are NOT in use:
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* `electronics-pcb` --- Debian packages for PCB development (meta package).
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* `fritzing` --- Easy-to-use electronic design software.
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* `geda` --- GPL EDA -- Electronics design software.
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* `gerbv` --- Gerber file viewer.
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* `lepton-eda` --- Lepton Electronic Design Automation.
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* `pcb` --- printed circuit board (pcb) design program.
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* `pcb2gcode` --- command-line tool for engraving PCBs using CNCs.
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* `pcb-rnd` - Modular Printed Circuit Board layout tool.
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* `visolate` - tool for engraving PCBs using CNCs.
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<div id='section-id-50'/>
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## Other Software
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Other PCBA software available under Free Software licenses.
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Used:
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* J-Tech Photonics LASER Inkscape Plugin.
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* `raster2gcode` --- Inkscape Plugin.
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Not Used:
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* `InteractiveHtmlBom` --- Interactive HTML BOM generation plugin for KiCad
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https://github.com/openscopeproject/InteractiveHtmlBom
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* `OpenPNP` --- Pick and Place software.
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* [`flatcam`](http://flatcam.org/) --- Free and Open-source PCB CAM.
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FlatCAM lets you take your designs to a CNC router. You can open Gerber, Excellon or G-code, edit it or create from scatch, and output G-Code. Isolation routing is one of many tasks that FlatCAM is perfect for.
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<div id='section-id-69'/>
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## Electronic Design Automation (EDA)
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To design PCBs, KiCAD is used.
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Export Gerber files for manufacturing.
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<div id='section-id-73'/>
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# PCB Manufacturing
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You can make your own PCB or have them made by numerous suppliers.
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Recommended suppliers (amongst many):
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* OSHPark --- Strong FLO supporters, high quality, quick turn, USA.
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* DirtyPCBs --- Lowest possible cost out of Shenzhen, China.
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* ProtoExpress -- Quick turn, high quality, high cost, USA.
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* Many others that also support KiCAD!
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<div id='section-id-85'/>
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## Board Types and Features
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FR1, FR4, etc.
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<div id='section-id-88'/>
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## Copper Layer
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Cu later.
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<div id='section-id-91'/>
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## Soldermask
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Green...
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<div id='section-id-94'/>
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## Silkscreen
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White...
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<div id='section-id-97'/>
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## Standards & QC
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Standards:
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* RoHS (no lead).
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* cf. NASA Standards.
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<div id='section-id-104'/>
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# PCB Assembly
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You can have a board assembled by a house such as ProtoExpress,
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or you can assemble it yourself. There is an endless variety of
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DIY approaches to this. This you have the PCB finished. You need to:
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* Source components.
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* Place components.
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* Solder Components.
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<div id='section-id-115'/>
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## Placement
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The many ways to place a part...
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* Fingers.
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* Tweezers.
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* Vacuum.
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* Pick and Place.
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What method is used depends on the type and size of the part
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and what equipment is available. We'll be working with SMT,
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BGA, and through hole parts.
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<div id='section-id-130'/>
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## Solder Paste
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To solder SMT parts to PCB.
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In use:
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* CHIPQUIK SMD291SNL50T3, 50g jar.
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* Zeph ZeroLead, 96.5Sn / 3Ag /.5Cu, 10cc syringe.
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<div id='section-id-139'/>
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## Solder Wire
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In use:
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* Kester K1000D, no clean, no lead, 0.8mm.
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* Kester Sn96.5Ag3.0Cu0.5, no clean, no lead, 0.8mm.
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<div id='section-id-146'/>
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## Flux
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In use:
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* Zephlux No Clean Flux, 14 gr. jar.
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<div id='section-id-151'/>
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## Flux Remover
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But you just put flux on...
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In use:
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* Zeph Flux Remover.
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<div id='section-id-158'/>
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## Low Melt Alloy
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To desolder, perchance.
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* Zeph ZERO No Lead Low Melt.
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<div id='section-id-163'/>
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## Solder Wick
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Solder wick, aka desoldering wire.
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In use: variety sizes.
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<div id='section-id-168'/>
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## Heat
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You need to melt that solder...
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* Solder Iron.
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* Skillet.
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* Oven.
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* Hot air pencil.
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* Hot air bath.
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<div id='section-id-181'/>
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# PCBA Processes
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Working with PCBs and components:
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<div id='section-id-184'/>
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## Solder through hole components with soldering iron
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HOWTO solder through hole components to a PCB with soldering.
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<div id='section-id-187'/>
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## Solder SMT components with soldering iron
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HOWTO Solder SMT components with soldering iron.
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<div id='section-id-190'/>
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## Solder SMT components with hot air
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HOWTO Solder SMT components with hot air.
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<div id='section-id-193'/>
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## Solder SMT components with oven
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HOWTO Solder SMT components with oven.
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<div id='section-id-196'/>
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## Solder SMT components with skillet
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HOWTO Solder SMT components with skillet.
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<div id='section-id-199'/>
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## Solder BGA components
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HOWTO Solder BGA components.
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<div id='section-id-202'/>
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## Rework through hole components
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HOWTO Rework through hole components.
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Current Practice:
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* [Through Hole Component Removal HOWTO]
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(HOWTO/through-hole-component-removal-HOWTO.md)
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<div id='section-id-210'/>
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## Rework SMT components
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HOWTO Rework SMT components.
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Current Practice:
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* [SMT Component Removal HOWTO]
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(HOWTO/smt-component-removal-HOWTO.md)
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<div id='section-id-218'/>
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## Rework BGA components
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HOWTO Rework BGA components.
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<div id='section-id-221'/>
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## Create solder paste stencil
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HOWTO Create solder paste stencil.
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Current Practice:
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* [HOWTO create a solder paste stencil with Inkscape]
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(HOWTO/laser-solder-paste-stencil-inkscape.md)
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<div id='section-id-229'/>
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## Apply solder paste with solder paste mask
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HOWTO Apply solder paste with solder paste mask.
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<div id='section-id-232'/>
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## Apply solder paste with syringe
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HOWTO Apply solder paste with syringe.
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<div id='section-id-235'/>
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## Apply solder paste with electronic syringe
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HOWTO Apply solder paste with electronic syringe.
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<div id='section-id-238'/>
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## Solder Pot
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HOWTO Use a solder pot.
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* [Solder Pot HOWTO]
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(HOWTO/solder-pot-HOWTO.md)
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<div id='section-id-244'/>
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# PCBA Testing
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Pins.
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<div id='section-id-247'/>
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# Equipment
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The equipment considered is what is generally available to
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hackerspaces. This leaves out industrial gear like large
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wave solder machines.
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<div id='section-id-252'/>
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## LASER
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LASERS can serve a few purposes in manufacturing PCBAs.
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Inexpensive LASER cutters are available at many hackerspaces.
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Inexpensive LASERs can be retrofit to RepRap 3D printers.
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* Cut solder paste stencils.
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* Etch paint, which is then chemically etched.
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* Board marking, such as serialization.
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<div id='section-id-263'/>
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## CNC
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Large CNCs are overkill for PCBA assembly.
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Very small CNCs can be used.
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CNCs are available at many hackerspaces.
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CNCs can be used to:
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* Engrave PCB.
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* Drill PCB holes.
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<div id='section-id-273'/>
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## 3D Printer
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RepRap 3D printers are available at many hackerspaces.
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3D printers can be used to:
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* Make CNC fixtures.
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* Make board holding fixtures.
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* Make other tools, etc.
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<div id='section-id-283'/>
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## Solder Station
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Solder station tools:
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* Soldering iron.
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* Hot air pencil.
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* Hot air bath.
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* Fume extrator.
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* PCB holder.
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* Lights.
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* Magnification.
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* Solder paste dispenser.
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* Vacuum pencil.
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* Oven.
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* Heat plate.
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* Solder pot.
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<div id='section-id-310'/>
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## Pick and Place
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A variety of free software compatible and open source hardware
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pick and place machines are available.
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* OpenPNP designs.
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* LitePlacer. Note, works with Free Software OpenPNP, but is
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non-commercial design licensed hardware. Manufacturer supplies
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proprietary application.
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<div id='section-id-320'/>
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# Production Boards
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Boards manufactured or slated to be manufactured.
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* Trellisboard --- Ultimate ECP5 board.
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https://code.forksand.com/forksand/fs-TrellisBoard
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* ULX3X --- ECP5 board.
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https://code.forksand.com/forksand/fs-ulx3s
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<div id='section-id-329'/>
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# Copying / License
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This document is available here:
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https://code.forksand.com/forksand/pcba/src/branch/master/README.md
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License: CC By SA 4.0 International and/or GPLv3+ at your discretion.
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Other code licensed under their own respective licenses.
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Copyright © 2019, Fork Sand, Inc.
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