Cirqoid – printed circuit board prototyping machine
cirqoid.com
cirqoid.com
Here's a nice hobbyist pick-and-place machine: http://briandorey.com/post/DIY-Pick-and-Place-V2-Project-Com... This one has a vision system to get precision alignment. In the era of the $10 cell phone camera module, there's no reason to have one without a vision system. You design some fiducial marks on the board, and the vision system goes looking for them to get precision alignment. This makes up for small errors in the board position. When putting down a part, the vision system matches up the expected pattern of pads with what it sees and fine-tunes the position. This is easier than trying to hold everything so rigid that blind placement works. A vision system also lets you check that you picked up a part properly from the feeder, and that it's in place properly after placement.
Your little assembly line is then a pick and place machine, a solder-paste dispensing machine, and a reflow oven, which can be a toaster oven with precision temperature controls. There are many small shops in Shenzhen like that.
It's really not that difficult; I'm not sure they even had a pick and place machine when they got started, the LNBs didn't have all that many components.
The outfit I worked for after leaving college in the late 80's shipped hundreds of boards a month doing everything manually. By the time they folded, the only change was sending them out for wave soldering.
These days I can outperform them with a solder paste stencil and a toaster oven. Blows my mind.
And I did a lot of thru hole soldering when I was growing up in the '70s; the LNBs were surface mount (one of the reasons they asked me to go that expo). Maybe there were some thru hold components I'm not remembering, but there was a definitely a lot of surface mounting (my intro to the concept, I think), and I e.g. remember seeing their reflow oven when I got a tour of the place.
Voltera: http://volterainc.com/ Voxel8 Tempo Automation: http://tempoautomation.com/
People are realizing that iterating on electronics is painful hence trying to fix it. The interesting part is the market size, unit costs etc. Also ability to do very small pitch ICs.
We got so desperate with pick and place that we literally 3D printed a 3D printer adapter combined with our vacuum pump and Pronterface. https://twitter.com/flairvents
http://www.thingiverse.com/thing:528114
http://www.amazon.com/gp/product/B003GWGUR6/ref=oh_aui_detai...
Pronterface:
https://github.com/kliment/Printrun
It should be noted that we only used this for the tiny pitch QFNs and other small components that we couldn't do by hand, the easier components we did with tweezers. Once we validated the design with a couple boards, we just had a bunch more assembled over in Freemont CA.
any chance you have a video of it in action?
I posted some more information about our capabilities in response to someone below. Let me know if anyone has any questions!
Another obvious improvement: offer a hot air nozzle tool, with a preheater in the base. It would be really neat to go from bare copper to an assembled PCB without moving the board.
Oh, and an automatic tool changer. :)
If you truly need a quick turnaround, pcbexpress can get you a slightly higher quality board tomorrow for less than $200. That's around 1/15th the cost of this device, and a better product (i.e. less likely to cause a problem which will waste a ton of your time)
The pick-n-place aspect is somewhat interesting, but HaD had a project for a $300 pnp machine; I expect to see something like it on kickstartr soon.
Also you can get one off simple 2 layer boards for $25.
Where? I haven't really looked into outsourcing it. I assume like most things it's a hefty cost for the first one due to setup and tooling, and the rest are dirt cheap. I'm a hobbyist so a mill like that is interesting, but as a hobbyist I'm not really aware of all the options. It seems much better than messing with etchant. The designs that use SMD components aren't going to work with breadboard. No vias as they are single layer.
There are Chinese ones as well that ship to you within a week.
Well what if someone in the U.S. bought this thing and offered a board tomorrow, but rather than $200 it was only $30? Would the speed/price make up for the quality?
Big issue I see is that this machine does not have a pressure foot. That's going to be a real issue keeping the milling depth consistent.
We don't have the resolution to get what most board houses can do, but we can reliably hit pitches (pin to pin spacing) of 800 microns. This allows us to build fully embedded fully 3d circuits using many of the surface mount chips on the market today.
As we make our machine more accurate we will eventually be able to hit 500 micron pitch and then we will be able to integrate BGA packages. We'll be there soon!
Also be careful of the dust. Especially from the fiberglass substrates. Its nasty stuff.
The most common and by far the least expensive is soldering a thin wire (or some TTH component's lead) between layers. Depending on the number of vias on your board it can be as entertaining as watching grass grow, but quite often it's the fastest way to get them done.
Another possibility is to press copper rivets (sometimes called eyelets). Rivets can be pressed sufficiently flat, thus allowing to put them under ICs (which is impossible with soldering approach). Though they need more space (i.e. outside diameter of the via needs to be larger) and tend to be less reliable.
There are other possibilities, including the actual electroplating process, but these tend to be fairly sophisticated and expensive.
The FAQ is at http://cirqoid.com/pages/faq, and of course linked in the tabs across the top of the page. Not very well hidden.