Sunday, August 14, 2016

PCB Prototype by Cu Deposition and Sn Plating

Take a Blank Epoxy Card. No Copper, just the glass epoxy card. It will not be copper clad. I am trying to explain the concept. The Glass Epoxy card as you know is Epoxy (Like Ciba Araldite) with glass fiber as filler. Maybe new technologies have come now. The fiber is for Reinforcement and Epoxy you know is a Marvel of an Engineering Material.

EE Design Library - Electronic Product Design Resource.

PCB Prototype by Cu Deposition and Sn Plating

PCB belongs to AVR JTAG adapter - MadWizard.org

In those days some people told me that these epoxy with glass fiber and iron flakes as powder are used to repair aircraft/spacecraft. It could be cast into a shape and even turned on lathe for making custom replacement components.

This nudged an idea, If we Screenprint a Mixture of Epoxy + Fine Iron Dust + ? over the blank Glass Epoxy card. The positive is used not the negative. That means Pads and Tracks on Positive create an Image of Pads and Tracks of this Epoxy/Iron paste on Glass Epoxy surface. Now Screenprinting done, let it dry. We can also be print a thin layer of epoxy pcb pattern and blow iron dust on it.

Dip this Printed Epoxy card with this iron/epoxy pattern; into a Copper Sulfate CuSO4 + ? + ? Solution. The ? has to figured by chemical engineers. I used to be good at Organic and Inorganic Chemistry, when i was young. The copper replaces/plates the iron powder and with some electrostatic and electrochemical methods the copper layer grows over the entire tracks and pads quickly. Now the card is Tin Sn plated to complete.

A single Prototype PCB is ready and no extra copper wasted. Copper and Tin was deposited.

2004 - delabs Notes

Saturday, August 13, 2016

Visual Embedded RAD for EDA

Just like an electronic circuit is a graphical representation of what will be on the PCB. Firmware development should be a 2D graphical diagram of what goes into eeprom.

An example is the Ladder Logic software that can program 80C51 types in a Fanuc, Allen Bradley or Siemens PLCs. Then many people can do at least restricted firmware programming for some embedded solutions.

Build a DMM or digital multi meter

Visual Embedded RAD. This is more like code snippets inserted in code in the background when user drags and drops a Hardware Function or Program Method. The Environment is Visual, but Code is compact as same modules or blocks used. There is no C or Intermediate Language. Visual to Binary Hex Direct.

(Ideas of delabs - Mar-04, Revised again - 4 April 2008, Nature - Open Source)

The Motor Bicycle

At late 40s I am into riding Geared Cycles. A Cycle Guru says it is the 'Cadence' in pedaling speed. What I need is a 'Mentor' for the Methodology behind Optimum Gear usage.

Mixed Circuits Analog with Digital

But some people are developing what will become well known as The Motor Bicycle, funny names.

Updated Nov 2015

Monday, August 08, 2016

Costing of EE Products

This is a Crude Costing Formulae based on my Ideas which is called "Gut-Feel Thumb-Rule Methodology." Even Though i am probably the only follower of this popular System, I am sure it is worth a casual Look.

Costing of EE Products

RM - Raw Material Cost         SP - Selling Price to Distributor

Reserves are for Dry days, Employee Fund is to reduce Attrition and Layoff. I was costing the products as a Proprietor, Managing Director and as an R&D Engineer too.

This post is just to enlighten you of the intricacies involved. It is merely the Tip of the IceBerg. You will need a Spreadsheet and lot of foresight and hindsight to make a practical costing.

Management Methodology 

This rule is for products made in good numbers. Large scale production costs may go down. Custom designed products made in small numbers the price may double. The cost of Engineering and IP has not been taken to consideration. It has been covered by a 10% Research Cost.

All this assuming we make products of reasonable quality and reliability. Build a reputation by good customer service when the product fails. So this will add into the cost depending upon the organization.

The grey areas in this costing are "Sourcing quality Raw Materials and Parts". Designing and Engineering "Reliable and Robust Products" . Customer Support at site or field may be expensive and warranty too.

Better to be Honest, Transparent and build a Brand Reputation for a Long Term company Success.