DIYing Huge BGA Packages

One day [Andy] was cruising around eBay and spotted something interesting. Forty Virtex-E FPGAs for two quid each. These are the big boys of the FPGA world, with 512 user IO pins, almost 200,000 logic gates, packed into a 676-ball BGA package. These are not chips designed for the hobbyist. These chips are not designed for boards with less than six layers. These chips aren’t even designed for boards with 6/6mil tolerances from the usual suspects in China. By any account, a 676-ball package is not like a big keep out sign for hobbyists. You don’t turn down a £2 class in advanced PCB design, though, leading to one of the most impressive ‘I just bought some crap on eBay’ projects we’ve seen.

halfbuiltThe project [Andy] had in mind for these chips was a generic dev board, which meant breaking out the IO pins and connecting some SRAM, SDRAM, and Flash memory. The first issue with this project is escape routing all the balls. Xilinx published a handy application note that recommends specific design parameters for the traces of copper under the chip. Unfortunately, this was a six-layer board, and the design rules in the application note were for 5/5mil traces. [Andy]’s board house can’t do six-layer boards, and their design rules are for 6/6mil traces. To solve this problem, [Andy] just didn’t route the inner balls, and hoped the 5mil traces would work out.

With 676 tiny little pads on a PCB, the clocks routed, power supply implemented, too many decoupling caps on the back, differential pairs, static RAM, a few LEDs placed just for fun, [Andy] had to solder this thing up. Since the FPGA was oddly one of the less expensive items on the BOM, he soldered that first, just to see if it would work. It did, which meant it was time to place the RAM, Flash, and dozens of decoupling caps. Everything went relatively smoothly – the only problem was the tiny 0402 decoupling caps on the back of the board. This was, by far, the hardest part of the board to solder. [Andy] only managed to get most of the decoupling caps on with a hot air gun. That was good enough to bring the board up, but he’ll have to figure some other way of soldering those caps for the other 30 or so boards.

29 thoughts on “DIYing Huge BGA Packages

  1. Should get himself at least a cheap Mylar/Kapton solder stencil and at least a toaster oven to do reflow. A vacuum pipette is also handy, this can be built with a syringe, a needle (cut short) and any small “aquarium pump” like suction pump.

      1. For many projects, the number of I/Os is more of a downside than an upside. I don’t think he’s even managed to break most of them out. 15K LUTs is towards the mid-range of Altera’s low-end MAX 10 FPGA series, which they seem to be positioning as a replacement for CPLDs and which are available as single-supply devices with a QFP packaging option – much nicer to work with, at least in theory.

        1. Kindof. I mean, if you don’t need the I/Os, don’t use the 676-ball package. Of course at some point you hit the smallest package in the family, and yeah, FPGAs tend to be bigger than they have to be, with the exception of the Lattice iCE40s, for the most part.

          If you’re talking about this project in specific, though, then you have to consider the price tag. You’re not getting *anything* close to that chip’s performance and I/O count at $3-4/part.

    1. Don’t think it is freely available. Article explicitly states “latest ISE version to work with these chips is 10.1”, which kind of implies it’s not available as a webpack version. However, chances are you can get an old, no-longer-used license for that piece of software that no-one in their right mind would enjoy using

  2. “His” board house can’t do 6-layers and 5mil trace/space? So, why not just go to someone who can do it then?
    I dont get why people artificially try to make stuff harder than it should be. 4-layers are cheaper you say? Well, if someone has enough money to impulse-buy a stack of FPGAs “just for fun” and make a pcb for them “just for fun”, the money argument seems extremely insignificant. The 6-layer board would not only help to get a good fan-out, at the same time you can make an extremely good decoupling cap with two internal planes and minimal prepreg thickness inside your pcb. I’m shure this would help a lot with stability, especially once you start to actually use a big chunk of that chips performance.
    Something else that seems a bit strange to me, why would you do length tuning on a diff pair line, and at the same time, not do any length tuning on the parallel RAM bus? The SRAM is probably not that critical, but the SDRAM shure would love to have your clock, adress and data arrive in sync. Ok, shure, if you want to push the limits of these LVDS data ports, length tuning on top of diff-pair routing and general impedance control is nice, but then you would actually use a connector designed for high speed diff-pair transmission with defined signal impedances, and definately not connect it to a 0.1″ standard IO-header…

    1. SDRAM is for 166MHz, so we are talking about 6ns period. Average propagation delay for microstrip is about 6 inches every ns. I would be surprise if those track skew are more than 0.5″ which means 100ps or 2% of the timing budget. That’s not worth fuzzing about.

    1. Definately not. I go down to 01005 sizes with hand soldering.
      Haven’t had the pleasure to do a design that needed smaller passives (008004 anyone?). Our assembly and reflow lines would have to get some serious upgrades to be able to pick and place and see these tiny components, and we do not see a good enough reason to upgrade our machines right now.

  3. Not a hack! This guy’s efforts are huge and totally professional, it seems that he just happens to do it in his spare time.

    I’m not knocking the article, it is valuable information and fascinating to see how the professionals do things, much appreciated.

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