Cutting out your own breakout boards

March 3, 2011 By 24 Comments

[Caleb] needed to use some surface mount components when prototyping. Instead of buy a breakout board he made one himself without doing any etching. The process he shows off in the video after the break uses copper tape to layout the traces for the board. It’s quite an interesting method which requires a sharp knife and a steady hand.

He used regular protoboard as a substrate and applied a layer of copper tape on the side without copper pads. From there he poked holes for the DIP pin headers. Now it’s time to do some cutting. [Caleb] removed the band of copper that would fall in between the pins of the surface mount device. He then tacked it in place with one dot of solder and drew the traces from the part to the pin headers. After removing the part he cut out the waste in between each line he drew with marker. What he’s left with is a set of thin traces that connect each pin of the surface mount component to the corresponding through-hole pin header.

This is very time-consuming, but then again so is soldering jumper wires to small-pitch components.

[Read more...]

Filed Under: misc hacks Tagged With: , , ,

DIY clamp helps with surface mount soldering

December 13, 2010 By 30 Comments

Hackaday writer [Gerrit Coetzee] built a simple clamp to aid in surface mount component soldering. This cheap, easily made device uses gravity to hold tiny components in place. The tip of the bolt is pointed, but gently like a ballpoint pen so as not to harm the components with a sharp tip. Roughly position your component, rest the tip of the clamp on its center, then nudge for final positioning. [Gerrit] also points out that this acts as a heat sink, helping to prevent damage to the component if you’re too lethargic with the soldering iron.

It seems like this device has been around in one form or another for quite a long time. But the best ideas do keep on popping up. Another nice tip to go along with this one is the use of a dowel when ironing during toner transfer for your PCBs.

Filed Under: tool hacks Tagged With: , , , ,

Skillet reflow controller

December 9, 2010 By 21 Comments

Using an electric skillet to reflow surface mount circuit boards is a popular alternate use for those kitchen appliances. The real trick is monitoring and controlling the temperature. [Mechatronics Guy] built his own skillet temperature controller using a thermistor, a solid state relay, and an Arduino.

He was inspired by [Ladyada's] work which used a servo to adjust the temperature dial on the skillet’s power supply. This started by attaching the thermistor to the bottom of the skillet using JB weld. since this area will be heating up he also attached a terminal block for connecting the feed wires as the heat would melt any solder joints. Those wires travel back to a control box housing the Arduino and solid state relay. To gain finer control over the heating element the relay is switched on and off, resulting in low-frequency Pulse Width Modulation, which should help maintain a consistent temperature better than just turning the temperature dial on the cord.

Pair this up with the vacuum tweezers hack and you’re on your way to a surface mount assembly line. If you want to see this process in action check out this post. It goes from stenciling, to populating, to reflowing in a toaster oven.

[Thanks Rob]

Filed Under: Arduino Hacks, tool hacks Tagged With: , , , , ,

Surface mount breakout boards

April 29, 2010 By 22 Comments

We got a hold of some DS3232 RTC chips in a 20-pin SOIC package. We’d like to have one that is breadboard compatible for easy prototyping but when we searched for SOIC20W breakout board artwork we found none. We used Eagle to design our own and you can see the finished product above which we made using the toner transfer method and cupric chloride.

You’ll find the artwork after the break in case you need to make your own breakout board some day. If you know of surface mount breakout board artwork that is freely available please leave the link in the comments for future use, or send it to us on our tips line and we’ll add it to the post.

Incidentally, the DS3232 is the same as the DS3231 used in the ChronoDot but with the addition of some SRAM. We’ll let you know if we come up with an interesting project for it.

Update: We added 28 SSOP to DIP artwork submitted by [Paul Dekker]

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Laser cutting solder stencils

March 19, 2010 By 13 Comments

Do you have access to a laser cutter? If so, you can use [Riley Porter's] method to cut your own solder stencils. He starts with the Eagle files and exports the Dimension and tCream layers to a PDF. That file is then processed using Ghostwriter, Gview, and finally, Corel draw. The result is a 1200dpi file to feed to your Epilog laser. Now you’re ready to stencil on the solder paste and populate the PCB.

[Thanks Travis Goodspeed]

Filed Under: tool hacks Tagged With: , , , ,

Double sided surface mount PCB population

October 25, 2009 By 18 Comments

Above is a video detailing one method for populating a two sided surface mount PCB. We covered using a stencil to apply solder paste for a PCB a few weeks ago. In the comments there was a debate about the virtue of using stencils as well as a question about how two sided boards are populated. This was a good question because reflowing a board twice can cause components on the underside to fall off.

[Wim L's] comment mentions that there are a couple of methods for two sided population. In the video you will see that a stencil is not being used, but instead, paste is applied by a pedal actuated syringe. The paste is applied to the underside of the board first, then a teeny dot of epoxy is added to hold the component in place. Each part is then positioned normally and baked in a reflow oven. This process both reflows the solder, and cures the epoxy. When the board is reflowed a second time, the epoxy holds the bottom components in place as the top solder reaches its melting point.

This method of applying solder paste is slower than using a stencil. But if done correctly, every component can get the amount of solder needed.

Filed Under: tool hacks Tagged With: , , ,

Build your own wristwatch

October 19, 2009 By 12 Comments

surface-mount-wristwatch

[rgbphil] has done a great job detailing how he built his Microdot wristwatch.This project is a lot more approachable than the pong watch we saw last month. If you’ve made a few printed circuit boards, but haven’t yet tried working with surface mount component, this is a great way to give it a try.

The parts count is pretty low, a few switches, resistors, capacitors, LEDs, a watch crystal, and a PIC 16F88 microcontroller.[rgbphil] is using a charlieplex so that a separate shift register is not needed to drive all of the LEDs. He goes into detail about the process of laying out the circuit. Some of the problems he encounters include how to manage all of the charlieplex connections in a simple way, how to program the chip once it’s on the board, and how to layout the controls for the device.

The display looks great in the video we’ve embedded after the break. We’re going to add these components to our next parts order and make this project part of the plan for getting us through the long cold winter ahead.

[Read more...]

Filed Under: led hacks Tagged With: , , , ,
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