The Complete Hardware Crash Course
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The document outlines a workshop on open-source hardware and software, focusing on the design process from concept to production, including considerations for industrial, mechanical, and electronic design. It covers essential tools, production strategies, and development methodologies, highlighting the Firefly Ice project as a practical example. Additionally, it provides insights into component sourcing, testing, and final assembly while encouraging collaboration and questions among participants.
![ManufacturingVendors
• Component Sourcing (meet, bundles)
• PCB Fabrication (local low volume)
• PCB Assembly (right fit local, similar
projects & tools)
• Plastics Manufacturer (right fit)
• Final Assembly & Test (self, interns) [learn &
improve the design]](https://image.slidesharecdn.com/thecompletehardwarecrashcourse-131201120610-phpapp01/85/The-Complete-Hardware-Crash-Course-40-320.jpg)
The Complete Hardware Crash Course
- 1. The Complete Hardware Crash Course SXSW 2014 Denis Bohm denis@fireflydesign.com Andrew Sanderson andy@modernfuelproducts.com
- 2. Team • Denis Bohm • Andrew Sanderson • Kyle Bohm
- 3. HO: Hands On • Follow the tiny URL for details. • Start anytime. Feel free to jump ahead. • This is a workshop, so please ask questions. • Keep it casual. Help each other out. Share what you are doing with others. • Introductions.
- 4. Introduction • Why use open source? • Overview of how to leverage open source hardware & software. • Tips to save iterations. • Walk through the typical steps from concept to production…
- 5. Our Focus • Quantity matters (1,000 is hard) • Starting from scratch vs iterating • Production has unique requirements
- 6. Open Source Checklist • Hardware (electronics, mechanicals) • Firmware (RTOS, driver, app) • Software (API, apps, storage, sites) • Production (sourcing, fixtures, program & test, FCC testing) • Tools (IDE, SCM, eCAD, mCAD)
- 7. Firefly Ice Project • Wearable & Internet of Things Platform • ARM Cortex M3, Bluetooth 4.0 LE Radio, USB, Accelerometer & Magnetometer, Rechargeable Battery, etc… • Open source hardware, firmware, software, production (and a couple of handy tools) • 1,500 Units for First Customer
- 8. HO:Try It Out • Instructions @ http://tinyurl.com/loc4qne • Open the Firefly Utility app • Wake & connect to the Firefly Ice in your parts kit • Play with the LEDs, check the battery level, and name it
- 9. Process • Now we are going to walk through the process of designing a product. • Normally, things happen intertwined and in parallel… But we will discuss them as separate items (industrial design, mechanical design, electronic design, etc)
- 10. HO:View Mechanicals • Instructions @ http://tinyurl.com/kx9nel5 • git clone https://github.com/denisbohm/ firefly-ice-mechanical.git • open firefly-ice.3dm in Rhino3D
- 11. Industrial Design • Materials, finishes, colors • Shape, locations of all visible features: LEDs & USB Connector, impact on PCB • Markings: Logo,Word-marks, FCC ID, etc • Mechanical considerations: seams, mold lines, etc…
- 12. Mechanical Considerations • Design for ease of assembly (no rework) • Design for molding (price, 4 pieces) • Robust design (drop test, USB wrenching)
- 13. Mechanical Design • Light pipes, color mixing, isolation, co- molding • USB opening (robustness, splash proofing) • Battery swell (add battery to 3D model) • Wire management (photos) • Mold design, surface finishes (draft, add plastic), thickness (drop test, opaqueness)
- 14. HO: Edit Mechanicals • Instructions @ http://tinyurl.com/l38r5az • Increase the post length • Export to STL for prototyping
- 15. Mechanical Prototyping • 3D Printing (Price vs Time) (Personal & Outsourced) • Milling (Personal & Outsourced) • Sections vs whole parts • Production materials vs prototyping • Colors & Finishes (sand, plate, paint, etc)
- 16. Mechanical Future • Band-Aid:Thinness & Flexibility • Waterproof: Charging • Clothing: Power & Communication
- 17. Software • CoreBluetooth, USB HID Manager • SDK API: detour, executor/observable, manager, sync • App: discovery, connect, communicate, active/inactive, background/foreground
- 18. HO: Using the API • Instructions @ http://tinyurl.com/knmmxod • git clone https://github.com/denisbohm/ firefly-ice-api.git • open MacOSX/FireflyGame/ FireflyGame.xcode
- 19. Q & A • And now for a short intermission…
- 20. Production • Manufacturing Plastic Parts (Molds (time) + sampling and tuning, then production run) • Sourcing Components (BOM Tool) • PCB Fabrication & PCB Assembly • Programming & Test (Fixture + Firefly Tool) • Final assembly (PCBA + Battery + Plastics)
- 21. Test Fixture • Mechanical design - spring pins for test points • Electrical design - PCB for mounting spring pins and eliminating wire management • Connectors (SWD, USB, battery, etc…) • Software design - program & test software using SWD
- 22. HO: Program & Test • Instructions @ http://tinyurl.com/ls7yt33 • Connect Test Fixture to laptop • run FireflyTool • press PCBA into fixture until complete • connect and uniquely name your device
- 23. Firmware • Source code: src/*.c,h • Boot loader, main firmware, test firmware, SWD programming firmware • Memory map & placement, startup code • Bluetooth Profile / nRFgo Studio • Hex & Elf
- 24. HO: Firmware Development • Instructions @ http://tinyurl.com/lyp6p3b • Debug hardware: JTAG, SWD, Cables • Target hardware: Firefly Ice PCBA • Tool Chain: gcc, gdb, FireflyFlash
- 25. Q & A • And now for a short intermission…
- 26. HO: Electronics • upverter @ http://tinyurl.com/mx8lv55 • PDF @ http://tinyurl.com/m9rcju5 • Schematics & Board Eagle files on GitHub • Multiple sheets & 4 signal layers • CadSoft EAGLE Layout + Schematic (Hobbyist $169, Standard $575)
- 27. Electronics • Eagle 6 • Firefly Ice: firefly-ice.sch,brd • Fixture: firefly-ice-fixture.sch,brd • Parts Library: firefly.lbr • Sourcing attributes on each component
- 28. Schematic Considerations • Power domains (voltage, switchable, translation) • Busses (pin count, speed, power, robustness) • Probe points (SWD, switches, USB, etc) • Wires vs SMT (motors, batteries, etc) • Power, availability, dimensions, fine pitch
- 29. Layout Considerations • Power planes, RF clearances, crystals • Probe pads (SWD, clearances, 1 sided) • Layers, pitches, in-pad/micro/blind/tented vias • Markings (copyright, model, revision, pads, placement) • Panelization (milling, mouse bites, fiducials)
- 30. Expansion Connector • 6-pin low profile SMT connector (2.25 mm + 2.5 mm = 4.75 mm) • 3 power pins: unregulated voltage (5V to 3.5V), system voltage (2.2V), ground • 3 data pins: I2C SDA, SCL, INT (or UART, or Low Energy Sense, or analog comparator, or GPIO)
- 31. HO: Sourcing & BOM • Instructions @ http://tinyurl.com/lhmx5ha • A prebuilt BOM release is in the GitHub firefly-production-tools/releases repository
- 32. BOM Tool • Reads sourcing attributes from schematic • Gets pricing information via OctoPart • Generates Bill Of Materials • Generates purchasing quantity for each distributor
- 33. HO: PCB To 3D • Instructions @ http://tinyurl.com/k9ualyy • A prebuilt PcbTo3D release is in the GitHub firefly-production-tools/releases repository
- 34. PCB to 3D • Reads printed circuit board layout • Writes Rhino 3D script • Script creates PCB and places Rhino components • Useful for checking PCBA with enclosure
- 35. HO: Bluetooth Direct Test Mode • Instructions @ http://tinyurl.com/kqvtjhe • Use one firefly in direct test mode to send test packets. • Use another firefly in direct test mode to receive test packets.
- 36. FCC • Preparing a test device with SMA connector • Complete sample device • Using a computer w/ USB for testing • Documentation • Markings
- 37. HO: Final Assembly • Instructions @ http://tinyurl.com/lzxkkpk • final assembly into plastics (snap fit)
- 38. Main Costs • Electronic Components 100 $50, 1,000 $25 • PCB Fabrication & assembly (10 $250, 100 $50, 1,000 $25) • Milling a plastic part $250+ ea @ FirstCut • Mold $3,500+ ea, $1 per set MOQ 1k • FCC Testing $6,500+ (w/radio, US only)
- 39. 10 100 1,000 Components $50 $35 $25 Milled Parts $1,000 $0 $0 Molds $0 $14,000 $0 FCC $0 $6,500 $0 PCBA $250 $50 $25 Cost Each $1300 $290 $50 Total Cost $13000 $29000 $50000 Cost Progression
- 40. ManufacturingVendors • Component Sourcing (meet, bundles) • PCB Fabrication (local low volume) • PCB Assembly (right fit local, similar projects & tools) • Plastics Manufacturer (right fit) • Final Assembly & Test (self, interns) [learn & improve the design]
- 41. DesignVendors • Product Design (everything in parallel) • Industrial & Mechanical • Electronics & Layout • Firmware • Device API (iOS & Mac OS X,Android, Windows, etc)
- 42. What’s on my Bench? • CNC Milling Machine • Microscope w/ Light, Camera, andVise • Oscilloscope with uA Current monitor • Soldering Station with SMT tweezers • Power Supply (on/off), Multi-Meter (uA), Wire Stripper, …
- 43. ThankYou Questions, comments, ideas? Denis Bohm denis@fireflydesign.com Andrew Sanderson andy@modernfuelproducts.com
- 44. How was the session? Feedback SXSW App Session Feedback 1. Express yourself 2. Help us get better 3.Earn rewards {Daily SXSW Posters + Grand Prizes} In 1 minute