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SXSW: Imagine a Practical, Low-Cost Circuit Board Assembly System (Video)
SXSW Create is one of a handful of sub-shows at SXSW which don't require an expensive badge — it's maker-oriented and small, and a few blocks from the slicker parts of the convention. (The local ATX Hackerspace was there showing off robots and giving out soldering lessons and blinkies, without a single corporate pitch.) Under the same tent, I met with Jeff McAlvay, co-creator of Board Forge, which Jeff hopes will make small-run circuit board creation as easy and accessible as small-scale 3-D printing has become in the last few years. ("Think MakerBot for electronics.") The prototype hardware McAlvay had on hand looks -- in fact, is a 3-D printer, albeit one lower-slung than the ones that make plastic doo-dads. That's because the Board Forge's specialized task of assembling circuit boards requires only limited vertical movement. It's using the open-source OpenCV computer vision software and a tiny camera mounted on a movable head to accomplish the specialized task of selecting and placing components onto the boards. The tiny electronic components are lined up in strips on one side of the device, where that smart head can grab them for placement. The brains of the operation include an Arduino-family processor for basic controls, and a Raspberry Pi for the higher-level functions like computer vision. The projected cost for one of these machines — about $2000 — should put instant-gratification machine-aided circuit creation in reach of schools and serious hobbyists, but there's plenty of work before it's set for sale to the public; look for a Kickstarter project in the next few months.
Ultimately, the machine will etch traces, apply solder paste, place components, cook, and test. Version 1.0 places components.
shit damn, I forgot the quotes and the snippy annoying RTFA comment.
A $2K device that does solder paste and Pick-and-Place is what we need. You can have circuit boards made easily and cheaply from a number of places. It's been a loooong time since I thought it was worth the time and hassle of playing in the soup myself. I don't see the point of trying to make PCBs at home any more. Toaster oven or hot plate soldering works great for suface mount. The two killers are 1) applying solder paste, and 2) pick and place. So, a cheap reliable stencil is one option for older. A friend of mine has a Mikini 1610L CNC mill, and we did a hack to add a manual solder paste syringe (one of the compressed-air driven hand-held units) as a tool head. Our first attempt got some nearly usable boards, but it would require tuning and another rev to get the right amount of paste and make it all work. Other people have done hobbyist grade Pick-n-place. Combining the two operations, adding the webcam for precise part orientation, and hitting $2K would be a game changer.
Actually a pick and place machine is precisely addressing the bottleneck if you need to make small runs. Sure, for a 1-off board it doesn't matter much. But if you want to make a run of 50 boards, you can get the bare PCBs made very cheaply, but assembling the boards is another matter altogether. (I have actually found a company that will assemble 50 boards for a reasonable price, but it would still be a lot better - even if it wasn't any cheaper - to have the assembly done genuinely "in house", not to mention a much faster turnaround time).
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