Project 1: Xilinx CPLD Programmer

I have no idea exactly how much this simple programmer would cost us if we were to buy it from the store. But it only took me less than four hours to solder the whole things. Below is the the schematics of the programmer, taken from here:

Below is the picture of the programmer:

This is the top side:

Bottom side:

The PCB track (before drilling):

The size of the first prototype is around 6.4 X 13cm. As you can see, soldering on breadboard is not very neat and hold the components as strong as it would on a fabricated PCB. The size of the PCB of the last picture is around 5.5 X 13cm. You would think that there's no much space saving, but the biggest advantage here is you can keep this board longer and carry it around without worrying the wires joints will get broken.

PCB Making Process Types

There are 3 types I use to make PCB:

1) Toner Transfer Methods
    This is a very basic PCB making process, where the layout is printed on "Transfer Paper" which is then transfered to the PCB. This methods works fine if the layout is not very dense.

2) Dryfilm Photoresist
    I use negative type films. Some of the populars ones are produced by DuPont ad MG Chemicals.

3) CNC Routing
    This is essentially to route the track by isolating the tracks using a CNC machine.

Welcome to Simple PCB Prototype Shop

 I believe many of us have or at least have tried designing and fabricating your own prototyping board. It could be as simple as to light up a few LEDs, or a more complicated design which involves a microcontroller, programmable logic device, memory IC, LCD display and a keypad.

Generally, steps involved are as follow:
1) Schematics Design:
    Depending on the software used, you might have to create the symbols and footprints of the component     you will use. If you're using for example Altium DXP, there are already major components already created in the standard library. I use Mentor Graphics DxDesigner to draw schematics. This software package does not provide a standard library, but you have to create your own (or buy it from a company specializing in creating this library).

2) Preparing Bill of Materials (BOM)
    From the step 1 above, you can output all the list components required for your projects. As the ordering process could a few days (or even weeks) to arrive, it's better to start ordering and sourcing all the materils brfore we proceed to the next step.

3) PCB Design
    From the schematics, the software will generate a "netlist" (i.e the point-to-point wiring information) of your design. The netlist is imported to layout software where you will the netlist connections where will complete the routing prosess. I use Mentor Graphics Expedition for this task.

4) Gerber Files Output
    This is a simple clicking process, where the PCB design software will output all the required layers for the PCB fabrication.

5) PCB Fabrication
    If you plan to send your design to a PCB factory, the process will temporarily stops here, before you could start populating the board with the components about 3~4weeks later when the PCB arrive. This will only makes you waiting, but will cost you around RM1800~2000 just to produce a 4" X 6" board. a more cost effective way is to send it to a PCB prototype shop, which will only cost you as low as RM50 and just a few days leadtime.

My Contact:
   If you would like me to design and fabricate your PCB, you can send me an email to simplepcb@yahoo.com or call 019-7044 304 (Man).

I need the following information:
1) Schematics in PDF format
2) Partlist / Bill of Materials
3) PCB outline i.e the dimension

If you stay around Johor Bahru area, we can meet up and discuss the details. I live in Skudai area.

Pricing:
For a standard size 4" x 6',  FR4 material, single sided PCB, with drill count <500, I will charge for RM50.
For drill counts >500 I have to charge more, to be discussed. For simple board, I think drill count 500 is sufficient.

Leadtime:
Since I'm doing this on part time basis, I need at least 5~7 days to complete a board.

Deliverables:
Apart from the finished board, I will also send to you:
1) The track layout in PDF
2) The assembly drawing in PDF
3) The NC drill file
4) I will NOT deliver the gerber files. This will cost additional RM25 if you need it.