5th Generation PCB boards using "3D Insertion Layer"

Prior art

The idea of making a pcb board directly via a RepRap machine is not new.

One such idea or concept is to use a "Solder Paste Syringe".
The method is described http://http//reprap.org/bin/view/Main/SolderPasteSyringe

"It might apply solder around all the pads on the board where component legs need to be attached. Next, place components onto the board where they need to go. It may be possible to use a heat gun or some other device to melt the solder en-masse. If not, then theres always hand soldering. Which would definitely be easier if there were solder pre-applied where you needed it. "

While Solder paste has worked for some test designs its very complex method of making pcb boards. My preferred method is to use the “Insertion Method" or system, described in 5th Generation Strengthen Builds w “Insertion”.

Suggested reading and review Prober's Ideas blogs:
5th Generation PCB 2D Layer
5th Generation Fixturing
5th Generation Strengthen Builds w “Insertion”
5th Generation PCB Terms and Use

I’ve received a great deal of interest in this so I’ve released a draft “drawing” and material, sorry about the mess.

5th Generation PCB boards using "3D Insertion Layer"

We also use our friendly and available product the paper clip to make the 3D Insertion Layer interconnections wires. Any conductive material can work, small nails, tumb tacks

Double click this rough sketch to view it full size.



While A = two layers of paper clip wire with X showing a non-conductive layer between one layer.
While B = two layers of paper clip wire with X showing a conductive connection of the 2 layers of paper clip wire layer.

While C = one layer of paper clip wire with X showing a non-conductive opening at the top layer non-conductive plastic. A stiff wire contact from the outside makes a conductive connection via the open hole X.

While D = one layer of paper clip wire with X showing paper clip wire set within a non-conductive opening at the top layer of non-conductive plastic. A header clip can be installed via this paper clip wire.

Top view E = a top view of A-D listed above.

While AA = two layers of paper clip wire with X showing a non-conductive layer between two conductive lines of paper clip wire.

While BB = two layers of paper clip wire with X showing a conductive connection of the 2 layers of paper clip wire layer. At X, two paper clip wires overlap each other.

While CC = one layer of paper clip wire with X showing a non-conductive opening at the top layer non-conductive plastic. The open hole X allows a stiff wire contact from the outside.

While DD = one layer of paper clip wire with X showing paper clip wire set within a non-conductive opening at the top layer of non-conductive plastic. A header clip can be installed via this paper clip wire.