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76 lines
5.3 KiB
Markdown
76 lines
5.3 KiB
Markdown
# Replacement LED PCBs
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> WARNING:
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> If you're reading this, you probably know the basics of soldering, including SMD components.
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>
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> If you're totally new to soldering, SMD might be a bit tricky. I'd suggest picking up an interesting keyboard project
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> (like the corne) and studying lots of youtube videos on the matter.
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>
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> Just remember to use solder with flux (Kester 63/37 .031 inch leaded solder recommended), and to use a smoke absorber
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> for your safety (Hakko FA400-04 recommended). When in doubt, flux flux flux.
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So, you want to manufacture your own LED PCBs? Well, here's a good way to go about that.
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1. Clone [Isola's repo](https://github.com/mnm-isola/wacca_ws2813) or download the ZIP from the Code button.
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`wacca_ws2813_rev20221021` is the revision we want. The main difference between revisions is that the capacitor at C9
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is SMD instead of THT. If you need THT, the previous August revision will do just fine.
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2. [Download KiCad](https://www.kicad.org/download/)
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3. Open `wacca_ws2813.kicab_pcb`.
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4. `File > Fabrication Outputs > Gerbers (.gbr)`. Set your output directory appropriately.
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5. Click `Generate Drill Files...` and ensure that the drill units are in millimeters.
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Click `Generate Drill File` and `Generate Map File`.
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6. Click `Plot`.
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You should now have 13 files. Zip these files up and go to your favorite PCB manufacturer (I like JLCPCB).
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**You need 60 PCBs to do a full replacement.**
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It should be as simple as uploading the zip, clicking through, and purchasing.
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I didn't change any of the default options other than making the PCB solder mask white.
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It took a total of 7 days for 200 PCBs to be produced, ship, and arrive from China to California.
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YMMV. About $45 for the PCBs and $47 for shipping.
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If someone has a cool WACCA-related silkscreen, please give. Maybe one of each navigator.
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Now that your PCBs are being fabricated, it's time to order the parts you'll need.
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[LCSC](https://www.lcsc.com/) is the recommended shop for these,
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they ship right out of Shenzhen and it's quite quick, considering.
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### BOM (for use with WS2813B-V5)
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| Footprint | Parts | Size | Value | LCSC | Remark |
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| --------- | ---------------------- | ----- | ------ | ---------------------------------------------------------------------------------------------------------------------------------------- | ----------------------------------------- |
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| C1-C8 | Not Needed | N/A | N/A | N/A | WS2813B-V5 do not require decoupling caps |
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| C9 | Tantalum Capacitor | 7343 | 220uF | [**C8024**](https://www.lcsc.com/product-detail/Tantalum-Capacitors_Kyocera-AVX-TAJD227K010RNJ_C8024.html) | Optional but adds protection. 10V. |
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| CN1, CN2 | JST XA | 3 pin | N/A | [**C265055**](https://www.lcsc.com/product-detail/Wire-To-Board-Wire-To-Wire-Connector_JST-Sales-America-B03B-XASK-1-LF-SN_C265055.html) | B03B-XASK-1(LF)(SN) |
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| CN3 | JST XA | 4 pin | N/A | [**C264994**](https://www.lcsc.com/product-detail/Wire-To-Board-Wire-To-Wire-Connector_JST-Sales-America-B04B-XASK-1-LF-SN_C264994.html) | B04B-XASK-1(LF)(SN) |
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| D1-D8 | Worldsemi WS2813B-V5 | N/A | N/A | [**C965558**](https://www.lcsc.com/product-detail/Light-Emitting-Diodes-LED_Worldsemi-WS2813B-V5_C965558.html) | |
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| R1, R2 | 0805W8F1000T5E | 0805 | 100R | [**C17408**](https://www.lcsc.com/product-detail/Chip-Resistor-Surface-Mount_UNI-ROYAL-Uniroyal-Elec-0805W8F1000T5E_C17408.html) | |
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| U1, U2 | MMBD1503A | N/A | N/A | [**C242273**](https://www.lcsc.com/product-detail/Diodes-General-Purpose_onsemi-MMBD1503A_C242273.html) | |
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So to do the math for you, to replace all of your lights, that's 60 PCBs you need.
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```
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60x C8024 [ships in multiples of 1]
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120x C265055 [ships in multiples of 10]
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60x C264994 [ships in multiples of 10]
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480x C965558 [ships in multiples of 5]
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120x C17408 [ships in multiples of 100, you'll have 80 extra]
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120x C242273 [ships in multiples of 5]
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```
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The parts at the time of writing were $61.94 with $14.24 for slower shipping from China to California.
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## Soldering it all together
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One way to shave a lot of time off mass producing these PCBs is to use solder paste and
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order a stencil from [OSH Stencils](https://www.oshstencils.com/). Upload the gerber zip,
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select the side that has all the LEDs as the top stencil (`wacca_ws2813_f_paste.gtp`),
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and make frameless stainless steel 5mil. Should cost about $50.
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Ordering the jig accessory can help as well,
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but you can just use other PCBs to hold the position of the one you're squeegeeing.
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Get some solder paste and apply it to the PCB using the stencil
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(spread over stencil and squeegee. if no stencil, careful syringing),
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apply the SMD components, put it in a modified oven or on top of a modified clothes iron
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(or maybe you can use hot air at low flow)
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