However, you can get reasonable quality masks for $150ish, and if you don't care about wafer yield, you can fit all of the layers on one mask. It's 1970s tech - 1:1 contact exposure, but you can hit a few microns.
393 karma · joined February 6, 2012
However, you can get reasonable quality masks for $150ish, and if you don't care about wafer yield, you can fit all of the layers on one mask. It's 1970s tech - 1:1 contact exposure, but you can hit a few microns.
I've written a little software package that implements all of the common math for calculating recipes and estimating properties. I'd love another developer on it, because right now it's sufficient for my use, but is also optimized for...me... which doesn't really make it great for anyone else. Really,I don't need any technical help, but more eyes would make things less idiosyncratic and insular.
I know a few QFT types - they tend to be decently intelligent and mathematically capable. Ok, they're more like wickedly smart...
For starters, I'd recommend the course notes to Stanford's EE261 (https://see.stanford.edu/materials/lsoftaee261/book-fall-07....) - well written, very funny, a nice level of rigour, etc...
I suppose I should recreate it, on an even larger scale. I just need to figure out some better way to power it...
I also build a swarm of throwies that used a single LED to synchronize their blinking. That project was much cooler, and I wish I had better documentation...
I'm not in that business, but I do deal with various safety concerns quite a bit. When faced with basic tools, the average person tends to have a terrifying combination of inventiveness and stupidity...
I'd really love to share the paper right now, but it's someone else's masters thesis that hasn't been released yet. If anyone is interested in it and can remember, ping me in a few months?
At this point, I have(2) an othermill and a pretty-near top-of-the-line LPKF S63 system + silkscreen and reflow capabilities, and am fairly impressed by both. I've been able to go from opening up a PCB editor to having a tested, functional board in under an hour, at least for simple breakouts.
The othermill is pretty flawed for PCB work, however. The spindle just isn't fast enough, cross layer alignment is inadequate, it doesn't have dust control for dealing with FR4 dust, etc. For good PCB routing, some sort of computer vision system for adjusting cut depths and picking up fiducials is also amazingly handy. That being said, we're really impressed with our othermill and do a lot of mechanical work on it - complex aluminum parts, engineering plastics, etc.
Cheap soldering for one-offs is pretty much solved at this point - laser cut a stencil on a decent laser cutter (which everyone should have, anyways), stencil paste, and reflow in a cheap Chinese oven with open source aftermarket firmware. You won't be able to do big BGAs or tiny (0201) passives, but who cares? If you have soldermask capabilities, either some photoresist method or laser cut kapton, soldering tricky components becomes much easier.
None of the additive (ink-based) systems have any hope of producing really useful boards - the electrical and thermal conductivity of real copper is pretty hard to beat, and doing anything controlled-impedance is pretty much out of the picture. With subtractive systems, you can just switch to 8+ oz copper or exotic substrates without changing the process materially...
Vias are tricky. LPKF makes two systems, one with conductive epoxy and the other with electrochemical copper, neither of which are quite satisfactory. Via rivets (or manually soldering wire) work for small boards, but are super tedious and not great for controlled impedance applications, either.
Being able to do decent multilayer boards is contingent on good vias, but in theory, the only other thing you need is a hot press for stacking things up?
Once you get into building complex multilayer boards, the time investment is just silly, even with perfectly calibrated processes, and you should just order from a board house and wait...
(1) I.e. boards better than DIY etching + manual soldering.
(2) Well, they're not actually mine, per se...
Youtube is one of the better resources right now, for anything other than really basic calculations. There seems to be a trend of old-school professional machinists documenting jobs they're working on - sort of a cross between a tutorial and virtual job-shadowing. Some nice users include oxtoolco, KEF791, Abom79, and mrpete222.
http://web.stanford.edu/group/siepr/cgi-bin/siepr/?q=system/...
[1] Faraday's 1861 lecture on platinum-group metals is a great example. Small-scale platinum casting is one of the big uses for oxyhydrogen - the combination of a high melting point and severe carbon embrittlement make H2 ideal for working with platinum.