Homebrew PCBs

Robert Hedan wrote:

> Has anyone had any experience using this product?
> http://www.internationaleyelets.com/
> It looks like we have to handle the eyelets individually.  Ugh...
> 
> I remember another manual system of thru-hole pin insertion, but I can't
> find the link any more.  It looked like a mechanical pencil with breakaway
> inserts.  You click out one pin from the tool, insert in the via hole, and
> break it off by leaning the tool.  Does anyone remember seeing this?
> 
> I was thinking of the drilling station and how to automate via insertion.
> If we mount this tool instead of the drill, the DRILL file already has all
> the coordinates for the vias.  The last thin I have to figure is how to
> break off the pin.  I was thinking of adding a 4th axis, making the drill
> rotate clockwise a few degrees or something.
> 
> Ideas, comments, insults?
> 
> Robert
> :)
> 


   Well realize that those via tubes cost money.  Plus the crimping operation is 
a PITA for them.  Could be done, but a PITA.  Their only real benefit is for 
through hole where a DIP pin goes, not hard to put seperate just wire vias right 
beside DIP pins etc.


   Feed wire through the board, 1/16" or so extra.  Move the board slightly, so 
a block just above and just below catch the wire and start to bend it.  Cut the 
wire just above the board, same 1/16" or so.  Push the board on through the 
blocks, bending the wire ends the rest of the way over.  You have a solid wire 
via, only needs the same soldering both sides required by the other types.  Just 
over 30 gauge hole and 30 gauge wire should work easily.  A breeze to do with a 
driller that slides the board instead of the drill etc.  Drill, wire feed, and 
bending blocks all stationary and within an inch or so of each other.

   And cast the right LED color over the board (Blue or green since copper is 
reddish) and the copper traces will be darker and a silver or tin plated wire 
will almost glow.  Easy to quickly solder all the vias both top and bottom if 
they stand out so well.

   Could probably do 100 vias within 5 minutes unattended, likely quite a bit 
faster than that.  Just come back and put it under the light, solder them all in 
a few minutes.

   I have many things on the burner at the moment, but this will be something 
done soon enough.  I have no doubt at all I can get this working, it's fairly 
simple.  Won't take any special parts either.  Several other methods could be 
made to work, but this is the most simple I've thought of so far.

   Custom machines like this are why I need to hurry and finish off the motor 
controller boards.  10 or 20 of them laying around and it'll be fairly easy to 
get this stuff going.

Alan