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272 lines
6.8 KiB
272 lines
6.8 KiB
# HOWTO make SMT Stencils with LASER
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This documents how to make solder paste stencils with a LASER
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using Inkscape. This is the preferred method over using FlatCAM,
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for now.
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## Equipment Used
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* LulzBot TAZ 6.
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* J-Tech Photonics 3.8W LASER.
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* Graytex Papers "Clear Transparencies for Color Laser Printers" (P/N 235-8511).
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5 mil (0.127 mm), clear.
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## Software Used
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* Debian.
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* KiCAD.
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* Inkscape.
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* J-Tech Photonics Inkscape Plugin.
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# KiCAD
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This HOWTO assumes you already have a KiCAD file ready.
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You will need to export the paste layers from KiCAD.
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This process is for one or two layer boards. You could make
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stencils for more layers, but that is only useful if you have a
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process to assemble PCBs with more than two layers.
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## KiCAD Steps
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Do thusly:
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* Open your KiCAD `.pro` file.
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* Click on "PCB Layout Editor" icon.
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* `File` --> `Export` --> `SVG...`.
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* `Output directory`: Where you would like the output file to go.
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* Under `Layers:`
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* Under `Copper Layers:` Uncheck all.
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* Under `Technical Layers:`
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Include the one layer you want to create a stencil for.
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Example: `F.Paste` for the front solder paste layer or `B.Paste` for the
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back solder paste layer.
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* Under `Options:`
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* `Default Pen Size`: `0.05 mm`. XXX confirm.
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* `Print Mode`: `Black and white`.
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* `SVG Page Size`: `Board area only`.
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* `Print Board Edges`: Unchecked.
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* `Print mirrored`: Unchecked.
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* `Pagination`: `One file per layer`.
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* Under `Output Messages` show debug as you like. You can `Save...`
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the file if you want, but it isn't needed. Useful just for debugging.
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* Now that everything is set up, hit the `Export` button. This
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will export a file to the `Output directory` specified above.
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* After `Plot`, hit the `Close` button.
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* Exit KiCAD: `File` --> `Exit`.
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# Inkscape
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In these steps, you take the `.svg` file exported from KiCAD,
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open it in Inkscape, and use a plugin to export gcode.
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## Inkscape Initial Setup
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The first time you do this process, you need to set up the
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Inkscape plugins. It is only needed the first time.
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* First you need to download the plugins. It is available from
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upstream here:
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https://jtechphotonics.com/Downloads/Inkscape/JTP_Laser_Tool_V2_2%20-%20inkscape%209_2%20version.zip
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* If the above URL is unavailable, there is a mirror in this repo here:
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https://code.forksand.com/forksand/pcba/src/branch/master/equipment/laser/inkscape/jtech
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* For example, it could be done thusly:
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```bash
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git clone https://code.forksand.com/forksand/pcba
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cd pcba/equipment/laser/inkscape/jtech
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mkdir ~/.config/inkscape/extensions/
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cp -p dxf_input.inx dxf_input.py laser.inx laser.py ~/.config/inkscape/extensions/
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```
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## Inkscape Steps
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Steps to generate gcode from an SVG file. Make sure you have
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installed the plugin the first time as illustrated in steps above.
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* Launch Inkscape.
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* Open the SVG file exported above by KiCAD.
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* Hit `CTRL-A` to `Select All`.
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* Hit `Shift-CTRL-G` to `Ungroup`.
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* Hit `Shift-CTRL-G` to `Ungroup` a second time. XXX check.
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* Select everything with `CTRL-a`. This assumes it is ungrouped.
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* Copy with `CTRL-c` or `Edit` --> `Copy`.
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* Create a new file with `CTRL-n` or `File` --> `New`.
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XXX Not sure why this is needed, but it works around erroneous
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gcode exports.
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* Paste contents with `CTRL-v` or `Edit` --> `Paste`.
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* Move selected contents to bottom left corner of document:
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In the task bar set `X:` to `0.000` and `Y:` to `0.000`.
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* Hit `4` for a decent zoom.
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* With everything still selected above, go to:
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`Extensions` --> `Generate Laser Gcode` --> `J Tech Photonics Laser Tool`.
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* In the `J Tech Photonics Laser Tool` dialog, set values thusly:
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* `Laser ON Command`: `M106`.
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* `Laser OFF Command`: `M107`.
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* `Travel Speed (mm/min or in/min)`: `1000`. XXX confirm.
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* `Laser Speed (mm/min or in/min)`: `500`. XXX confirm speed for transparencies.
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* `Laser Power S# (0-255 or 0-12000)`: `255`.
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* `Power-On Delay (ms or s)`: `0.0`.
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* `Passes`: `1`.
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* Pass Depth (mm or in): `1.0`.
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* `Directory:` Location you want to export the file.
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Use `.gcode` extension.
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* `Add numeric suffix to filename`: Unchecked.
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You can check if you want to do different versions each export.
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* `All Units (mm or in)`: `mm`.
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* `Live preview`: Unchecked. Optional.
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* When it is all set, hit the `Apply` button to generate the
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gcode.
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* Hit the `Close` button.
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* The generated gcode should show a bunch of blue arrows
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and similar, showing what has been generated (only in
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`Live preview` mode ?).
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* Inspect newly created gcode file to make sure the values are
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sane. Not sane values: `G1 X13004. Y-23242.76`. Sane values:
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`G1 X33.0302 Y20.0467`.
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* Hit `Close` button.
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* `File` --> `Quit`.
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# LASER
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## Setup
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This assumes the J-Tech Photonics LASER is set up and the TAZ is
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flashed with Marlin firmware from here:
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https://code.forksand.com/forksand/marlin-lulzbot-laser
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The build plate should be a 6mm thick (XXX check number)
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aluminium plate on top of the printers' bed. The printers'
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heatbed and glass should be removed.
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Make sure there is very good ventilation.
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* Perhaps add a gcode header/footer to the file.
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* Copy the new `.gcode` file to SD card. Such as:
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```bash
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sudo mount -o uid=1000 /dev/sdc1 /mnt
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mkdir /mnt/awesome/
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cp awesome.gcode /mnt/awesome/
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sync
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sync
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sync
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sudo umount /mnt
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sleep 5 # make sure the SD card has time to write before removing
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```
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* PUT ON PROTECTIVE EYE WEAR!
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* Power off LASER.
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* Disable LASER by removing key.
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* Power off printer.
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* Insert SD card into printer.
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* XXX Tape transparency and paper together? XXX
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* Place the transparency on top of THREE blank sheets of paper.
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Position the transparency in landscape mode, unless portrait mode is needed.
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Bottom left of transparency should be in front left corner on
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printer.
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* Secure the transparency/paper sandwich to the aluminium plate and bed
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with three large paperclips.
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* Slowly move toolhead to position where you want the bottom
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left corner of the stencil to begin (e.g. X=0, Y=0 of the stencil). It is
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probably best to have a margin of 50mm around the edges (XXX number).
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Make sure the LASER will be past the clips holding the transparency in place.
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* Power on printer.
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* Make sure the Z height of LASER toolhead is good with jig.
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Jig should be 40mm tall (XXX check number). It is presumed the LASER
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has good focus at the toolhead jig height.
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* If Z height needs adjustment, in printer LCD, go to Z movement
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and move to the correct height. (XXX menu sequence).
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* BE SURE TO PUT ON PROTECTIVE EYE WEAR!
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* Turn key on LASER to enable.
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* Power on the LASER via the power switch.
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* If fan on the LASER PCB doesn't start, press `RESET` button on PCB.
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* NOTE, LASER WILL TURN ON IN NEXT STEP!
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* In printer LCD, go to print from SD card, and print the gcode file
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generated above.
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* Time to cut depends greatly on board complexity, but in general
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it's less than 30 minutes.
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* Power off LASER.
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* Disable LASER by removing key.
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* Power off printer.
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* Remove paper clips.
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* Remove stencil.
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* Compare stencil to PCB.
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