Tuesday, December 1, 2009

5th Generation PCB 2D Layer

Use of the 2D Insertion Layer

2D Insertion Layer = Flat Foil type builds made of conductive materials.

Sticking a 2D flat piece of material onto a RepRap build might contain some sticking issues with existing build material as new hot material is added. The Flat Foil type material(s) builds made of conductive materials might not adhere to the build. The problem has been addressed by the “Insertion process” for composite builds. This process was covered in detail in an earlier blog.

Example of making a working build:
Aluminum foil is a cheap, durable, and workable “2D Insertion Layer” material. We can obtain other foils from “Craft Stores” etc. but IMHO is a great starting point.

1) Our PCB board design will contain its first build layer the “Insulate Layer”.
2) our build will contain several “Assembly connections”.
3) Our “2D Insertion Layer” is placed on the “Insulate Layer”. To lock the foil firmly on to our “Insulate Layer” we use a two step process. We take either “Internal connection” materials i.e. paper clip wire or “Insulated connection” material such as tooth picks. We press down the connections to lock down the foil firmly.
4) Next we make the product permanent by adding “Assembly connections”. This could build in or cover the paper clip or tooth pick materials. The foil is now locked in and other layers can be added until a full build is made.

Some detailed planning and testing will be required to make a high quality pcb build in production mode i.e. several copies. The concept however is sound. Stepper Motor assemblies cheap and easy to make.

The real beauty of this process is that once perfected, we can build in electrical items anywhere within plastic materials a Grand Hope!

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