Introduction
Hey there, fellow engineers! We’re Tinkerstruct, an educational electronics kit company, and we’re excited to share our journey of manufacturing NANDBoards, which help solve Boolean algebra challenges. Our mission is to enhance STEM education in the UK, with a strong focus on education kits, services, and STEM demonstrations, all provided through non-profit collaborations with schools and universities.
We were recently awarded funding from the RS Components Student Fund competition, which went towards supporting our prototyping and kit development - namely towards the purchase of our xTool Laser Cutter for making electronics enclosures and packaging designs. We are excited to share our story and will to take you behind the scenes of our development and manufacturing process. This article explains our PCB manufacturing process and how we created our NANDBoard kit to help teach Boolean Algebra in a practical and engaging way.
Development Process
Circuit Design: It all starts with designing the circuit. Using advanced CAD software, we create a detailed schematic that outlines the electrical connections and components needed for the NANDBoard. This design phase is crucial as it sets the foundation for everything that follows.
Solder Paste Application: Once the design is finalized, we move on to applying solder paste. A solder paste application machine precisely deposits solder paste onto the PCB pads where components will be placed. This step ensures that the components will adhere correctly during soldering.
Pick and Place Machine: Next up is the pick and place machine. This automated marvel accurately places surface-mount components onto the PCB. It picks components from reels and places them onto the board according to the design specifications. The precision of this machine is vital for the final product's functionality.
Reflow Oven: After the components are placed, the PCB is transferred to a reflow oven. The oven heats the board to a specific temperature, causing the solder paste to melt and form solid solder joints. This process securely attaches the components to the PCB, ensuring reliable electrical connections.
Conveyor Belts: Throughout the manufacturing process, conveyor belts transport the PCB from one machine to the next. These belts ensure a smooth and efficient workflow, minimizing the risk of damage and contamination.
Laser Cutting and Engraving: Thanks to the generous funding from our partner company, Tinkerstruct was able to purchase a state-of-the-art laser cutting machine. We use this machine to engrave the boxes in which the NANDBoards are supplied. Each box is meticulously engraved with the logo and name of the company, adding a professional and personalized touch to the packaging. We have prototyped the laser cutter for the creation of electronics enclosures and are considering other applications such as stamps, however, these new designs are still in the early stages.
Challenges and Solutions
Manufacturing the NANDBoard comes with its own set of challenges. One of the primary challenges is ensuring the accuracy of component placement. To overcome this, we use high-precision pick and place machines and regularly calibrate them to maintain their accuracy. Another challenge is achieving consistent solder joints, which we address by carefully controlling the reflow oven's temperature profile.
Conclusion
By sharing some of our development process, we hope to inspire and educate others in the engineering community. Our kits are designed, developed, tested, incrementally prototyped and eventually scaled to larger volumes by the Tinkerstruct team and with the support of Elliptic Systems manufacturing. As a fully equipped engineering space, we hope to support fellow engineers and bring their ideas to life.
Tinkerstruct Ethos
At Tinkerstruct, we believe in fostering a hands-on, experimental approach to learning and innovation. Our ethos is centered around empowering students and engineers to actively participate in maker-like, hardware-based projects. We aim to bridge the gap between theory and practice by providing tools and resources that make complex concepts more engaging and accessible. We are always excited to work on new projects with educators, schools, universities and other collaborators.
If this article has been of interest to you, please don't hesitate to contact us as we'd be happy to learn about your journey and explore ways in which we can work together.
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