Sketch of the two proprietary carriers showing their differences - one of them has a cutout under the antenna, while the other one does not.

Design Your CM4 Carrier With WiFi Performance In Mind

June 27, 2022 by Arya Voronova 7 Comments

The Raspberry Pi Compute Module 4 has a built-in WiFi antenna, but that doesn’t mean it will work well for you – the physical properties of the carrier board impact your signal quality, too. [Avian] decided to do a straightforward test – measuring WiFi RSSI changes and throughput with a few different carrier boards. It appears that the carriers he used were proprietary, but [Avian] provides sketches of how the CM4 is positioned on these.

There’s two recommendations for making WiFi work well on the CM4 – placing the module’s WiFi antenna at your carrier PCB’s edge, and adding a ground cutout of a specified size under the antenna. [Avian] made tests with three configurations in total – the CMIO4 official carrier board which adheres to both of these rules, carrier board A which adheres to neither, and carrier board B which seems to be a copy of board A with a ground cutout added.

After setting up some test locations and writing a few scripts for ease of testing, [Avian] recorded the experiment data. Having that data plotted, it would seem that, while presence of an under-antenna cutout helps, it doesn’t affect RSSI as much as the module placement does. Of course, there’s way more variables that could affect RSSI results for your own designs – thankfully, the scripts used for logging are available, so you can test your own setups if need be.

If you’re lucky to be able to design with a CM4 in mind and an external antenna isn’t an option for you, this might help in squeezing out a bit more out of your WiFi antenna. [Avian]’s been testing things like these every now and then – a month ago, his ESP8266 GPIO 5V compatibility research led to us having a heated discussion on the topic yet again. It makes sense to stick to the design guidelines if WiFi’s critical for you – after all, even the HDMI interface on Raspberry Pi can make its own WiFi radio malfunction.

Injection Molds: Aluminum Or Resin?

June 27, 2022 by Al Williams 11 Comments

[JohnSL] and his friend both have injection molding machines. They decided to compare the aluminum molds they usually use with some 3D printed molds created with a resin printer. They used two different resins, one on each side of the mold. You can see a video of the results below.

One half of the mold used ordinary resin while the other side used a resin that is made to hold up to higher temperatures. As you might expect, the lower-temperature resin didn’t stand up well to molten plastic. However, the higher temperature resin did somewhat better. It makes sense, though, that an aluminum mold draws more heat out of the plastic which is helpful in the molding process.

The higher temperature — and more expensive — resin did seem to hold up rather well, though. Of course, this was just to test. In real life, you’d want to use the better resin throughout.

No surprise, the resin molds didn’t last nearly as long as a proper mold. After 70 shots, the mold was worn beyond what you’d want to use. So not necessarily something you’d want to use for a real production run, but it should be enough for a quick prototype before you go to the expense of creating a proper mold.

We wonder if there are some other tricks to get better results. A comment from [TheCrafsMan] suggests that clear resin UV cures better, and that might produce better results. In fact, there are a lot of interesting comments on the video from people who have varied experiences trying to do the same thing.

If nothing else, watching the mill cut through the aluminum around the 15-minute mark is always interesting to watch. If you don’t already have an injection molding setup, you can always build one. We’ve seen more than one design.

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