yellowberryHN_redive/docs/guide/led-pcb.md

Replacement LED PCBs

So, you want to manufacture your own LED PCBs? Well, here's a good way to go about that.

1. Clone Isola's repo or download the ZIP from the Code button https://github.com/mnm-isola/wacca_ws2813. wacca_ws2813_rev20221021 is the revision we want (the main difference is that the capacitor at C9 is SMD instead of THT. if you need THT, the previous August revision will do just fine)
2. Download KiCad https://www.kicad.org/download/
3. Open wacca_ws2813.kicab_pcb
4. File --> Fabrication Outputs --> Gerbers (.gbr). Set your output directory appropriately.
5. Click "Generate Drill Files..." and ensure that the drill units are in millimeters. Click "Generate Drill File" and "Generate Map File"
6. Click "Plot"
7. You should now have 13 files. Zip these (select all, right click, send to, compressed zip folder) and goto your favorite PCB manufacturer (i like JLCPCB). You need 60 PCBs to do a full replacement. It should be as simple as uploading the zip, and clicking through and purchasing. I didn't change any of the default options except to make the PCB solder mask white. It took a total 7 days for 200 PCBs to produce, ship, and arrive from China to California. YMMV. About $45 for the PCBs and $47 for shipping.

If someone has a cool WACCA related silkscreen, please give. Maybe one of each navigator.

Now that your PCBs are fabricating, it's time to order the parts you'll need. https://www.lcsc.com/ is the recommended shop for these, they ship right out of shenzhen and it's quite quick, considering.

BOM (for use with WS2813B-V5)

Footprint	Parts	Size	Value	LCSC	Remark
C1-C8	Not Needed	N/A	N/A	N/A	WS2813B-V5 do not require decoupling caps
C9	Tantalum Capacitor	7343	220uF	C8024	Optional but adds protection. 10V.
CN1,CN2	JST XA 3 pin			C265055	B03B-XASK-1(LF)(SN)
CN3	JST XA 4 pin			C264994	B04B-XASK-1(LF)(SN)
D1-D8	Worldsemi WS2813B-V5			C965558
R1,R2	0805W8F1000T5E	0805	100R	C17408
U1,U2	MMBD1503A			C242273

So to do the math for you, to replace all of your lights, that's 60 PCBs you need.

60x  C8024 [these ship in multiples of 1]
120x C265055 [these ship in multiples of 10]
60x  C264994 [these ship in multiples of 10]
480x C965558 [these ship in multiples of 5]
120x C17408  [these ship in multiples of 100, you'll have 80 extra]
120x C242273 [these ship in multiples of 5]

The parts at the time of writing were $61.94 with $14.24 slower shipping from China to California

Soldering it all together

If you're reading this, you probably know the basics on soldering and soldering SMD components. If you're totally new to soldering, SMD might be a bit tricky. I'd suggest picking up an interesting keyboard project (like the corne) and studying lots of youtube videos on the matter. Just remember to use solder with flux (kester 63/37 .031 inch leaded solder recommended), and to use a smoke absorber for your safety (Hakko FA400-04 recommended). When in doubt, flux flux flux.

One way to shave a lot of time off mass producing these PCBs is to use solder paste and order a stencil from https://www.oshstencils.com/ Upload the gerber zip, select the side that has all the LEDs as the top stencil (wacca_ws2813_f_paste.gtp), and make frameless stainless steel 5mil. Should cost about $50. Ordering the jig accessory can help as well, but you can just use other PCBs to hold the position of the one you're squeegeeing. Get some solder paste and apply it to the PCB using the stencil (spread over stencil and squeegee. if no stencil, careful syringing), apply the SMD components, put it in a modified oven or on top of a modified clothes iron (or maybe you can use hot air at low flow)