You can find flex PCBs in just about every single piece of consumer electronics. These traces of copper laminated in sheets of Kapton are everywhere, and designing these cables, let alone manufacturing them, is a dark art for the garage electronics wizard. Having these flat flex cables and PCBs manufactured still requires some Google-fu or a contact at a fab house, but at least now designing these cables is a solved problem.
[Oli] needed a way to connect two PCBs together over a moving part. Usually this means some sort of connector or cable, but he’s developed an even better solution – flexible PCB connections. To generate these copper traces sandwiched between a few layers of Kapton, [Oli] wrote a Python script to take a set of parameters, and produces an design for Eagle that includes all the relevant bits.
Of course, with a flexible PCB layout, the question of how to get these manufactured comes up. we’ve seen a few creative people make flexible PCBs with a 3D printer and there’s been more than one Hackaday Prize project using these flex PCBs. [Oli] says any manufacturer of flexible circuits should be able to reproduce everything generated from his script without much thinking at all. All we need now is for OSH Park to invent purple Kapton.
You can grab [Oli]’s script on his GitHub.
KiCAD remains a popular tool for designing PCBs and other circuits, and with good reason: it’s versatile and it’s got pretty much everything needed to build any type of circuit board you’d want. It also comes with a pretty steep learning curve, though, and [Jeff] was especially frustrated with the bill of materials (BOM) features in KiCAD. After applying some Python and Kivy, [Jeff] now has a BOM manager that makes up for some of KiCAD’s shortcomings.
Currently, the tool handles schematic import, like-component consolidation, and a user-managed parts database that can be used to store and retrieve commonly used parts for the future. All of the changes can be saved back to the original schematic. [Jeff] hopes that his tool will save some time for anyone who makes more than one PCB a year and has to deal with the lack of BOM features native to KiCAD.
[Jeff] still has some features he’d like to add such as unit tests, a user guide, and a cleaner user interface. What other features are you anxious to see added to KiCAD?
This script is a great tool for anyone who has had similar frustrations. KiCAD is popular to modify and expand, too: there have been tools for mechanical CAD export, a parts-generator and cost-tracker, and an Eagle to KiCAD converter if you’re thinking of making the switch.
Work on HaDge – the Hackaday con badge, continues in bits and spurts, and we’ve had some good progress in recent weeks. HaDge will be one conference badge to use at all conferences, capable of communicating between badges.
Picking up from where we left off last time, we had agreed to base it around the Atmel D21, a 32-bit ARM Cortex M0+ processor. To get some prototype boards built to help with software development, we decided to finish designing the HACK before tackling HaDge. HACK is a project that [Michele Perla] started that we have sort of assimilated to act as the prototyping platform for HaDge. We wanted a compact micro-controller board and hence opted for the SAM D21E – a 32 pin package with 26 IO’s.
[Michele Perla] had earlier designed HACK based on the larger 32 pin SAM D21G and used Eagle to draw the schematic and layout. Using the Eagle to KiCad script, he quickly converted the project and got on to making the board layout. I took up the rear guard, and worked on making his schematic (pdf) “pretty” and building up a schematic library of symbols. While [Michele] finished off the board layout, I worked on collecting STEP models for the various footprints we would be using, most of which I could get via 3dcontentcentral.com. The few I couldn’t were built from scratch using FreeCAD. The STEP models were converted to VRML using FreeCAD. Using [Maurice]’s KiCad Stepup script, we were able to obtain a complete STEP model of the HACK board.
HACK is now ready to go for board fabrication and assembly. We plan to get about 20 boards made and hand them out to developers for working on the software. The GitHub repository has all the current files for those who’d like to take a look – it includes the KiCad source files, PDFs, gerbers, data sheets and images. The board will be breadboard compatible and also have castellated pads to allow it to be soldered directly as a module. Let us know via group messaging on the HACK project page if you’d like to get involved with either the software or hardware development of HaDge.
In a forthcoming post, we’ll put out ideas on how we plan to take forward HaDge now that HACK is complete. Stay tuned.
One barrier for those wanting to switch over from Eagle to KiCad has been the lack of a way to convert existing projects from one to the other. An Eagle to KiCad ULP exists, but it only converts the schematic, albeit with errors and hence not too helpful. And for quite some time, KiCad has been able to open Eagle .brd layout files. But without a netlist to read and check for errors, that’s not too useful either. [Lachlan] has written a comprehensive set of Eagle to KiCad ULP scripts to convert schematics, symbols and footprints. Board conversion is still done using KiCad’s built in converter, since it works quite well.
Overall, the process works pretty well, and we were able to successfully convert two projects from Eagle. The entire process took only about 10 to 15 minutes of clean up after running the scripts.
The five scripts and one include file run sequentially once the first one is run. [Lachlan]’s scripts will convert Eagle multi sheet .sch to KiCad multi sheets, place global and local net labels for multi sheets, convert multi part symbols, build KiCad footprint modules and symbol libraries from Eagle libraries, create a project directory to store all the converted files, and perform basic error checking. The Eagle 6.xx PCB files can be directly imported to KiCad. The scripts also convert Via’s to Pads, which helps with KiCad’s flood fill, when Via’s have no connections – this part requires some manual intervention and post processing. There are detailed instructions on [Lachlan]’s GitHub repository and he also walks through the process in the video.
Continue reading “Eagle to KiCad made easy”
A ton of open source hardware projects make their way onto Github, and Eagle is one of the most popular tools for these designs. [TomKeddie] came up with the idea of searching Github for Eagle files containing specific parts at Hacker Camp Shenzhen, and a method of scraping useful ones.
The folks over at Dangerous Prototypes used this to build the Github Hardware Search tool. Simply enter a part number, like “ATmega328P”, and you’ll receive a list of the designs using that part. You can then study the design and use it as a reference for your own project. You can also snag library files for the parts.
Of course, there are some limitations to this. The most obvious one is the lack of quality control. There’s no guarantee that the design you find works, or has even been built. Also, it only works for Eagle 6+ files, since prior versions were not XML. You can read more about the design of the tool over on Dangerous Prototypes.
[Burt Rutan] is someone who needs no introduction. Apparently, he likes the look of the Icon A5 and is working on his own version.
Earlier this week, the US Air Force lost a few satellites a minute after launch from Barking Sands in Hawaii. This was the first launch of the three stage, solid fueled SPARK rocket, although earlier versions were used to launch nuclear warheads into space. There are some great Army videos for these nuclear explosions in space, by the way.
[Alexandre] is working on an Arduino compatible board that has an integrated GSM module and WiFi chip. It’s called the Red Dragon, and that means he needs some really good board art. The finished product looks good in Eagle, and something we can’t wait to see back from the board house.
The Chippocolypse! Or however you spell it! TI is declaring a lot of chips EOL, and although this includes a lot of op-amps and other analog ephemera (PDF), the hi-fi community is reeling and a lot of people are stocking up on their favorite amplifiers.
[Jeremy] got tired of plugging jumper wires into a breadboard when programming his ATMega8 (including the ‘168 and ‘328) microcontrollers. The solution? A breadboard backpack that fits right over the IC. All the files are available, and the PCB can be found on Upverter.
In case you haven’t heard, we’re having a Super Conference in San Francisco later this week. Adafruit was kind enough to plug our plug for the con on Ask an Engineer last week.
A couple of days back, we wrote about the HACK – a prototyping platform designed by [Michele Perla] based on the Atmel SAM R21 MCU. It’s one of the new breed of devices consisting of an ARM Cortex-M0 MCU + IEEE 802.15.4 Wireless radio bundled together. This was exciting since we could pack a lot of punch in the HaDge hardware. We planned to use the same design later to power the HaDge. Building HACK would have allowed us to get it in the hands of the software team, while the hardware folks worked on the real HaDge layout.
The HACK design was ready for review and we asked around to verify the antenna layout, which was the part we were not too sure about. We asked Atmel for help with verifying the layout. That’s when we had the facepalm moment. They asked us – “What about FCC certification?” Since we plan to build the badges in quantities of a few hundred at the very least, it’s obvious we cannot escape from FCC certification. A design based around the R21 is ruled out – the cost of obtaining approval is pretty high. This means we need to punt the R21 and instead use an off-the-shelf radio module which is already FCC certified. Sigh.
Now the good news. This is a setback in terms of time, and effort put in by [Michele]. But beyond that, we’re good to go back to the drawing board and start afresh. First off, we decided to revert back to the Atmel D21 as the main controller. It’s a fairly decent MCU, and there’s a fairly robust tool chain available that a lot of people are familiar with. For the Radio, we are looking at some of these available options :
The last one from Microchip looks quite promising. But we’re open for better and cheaper suggestions, so please chime in with your comments.