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ZAM Badge 2024

Überblick

Bei der Planung des VULCA-Treffens kam die Idee eines Badge als Konferenzpräsent und Lötübung auf. Die Idee besteht darin, die folgende Grafik zu nehmen und diese in eine Leiterplatte mit blinkenden LEDs hinter dem Auge und den Buchstaben umzuwandeln.

Original.png

Projekt-Metadaten

ZAM-Badge-24 GitHub Repository

Jochen Hunger jochen.hunger@betreiberverein.de

Steve Mayze smayze@yahoo.com

Logbuch / Schritte

Tag 1 Zusammenarbeit


 I turned graphics into PCBs before but I was further inspired by Working with artists to design beautiful boards at KiCon Europe 2024. The first thing was to come up with the concept. Given the original graphic, I outlined a possible arrangement of the PCB layers.

Draft1.png

Based n this, Jochen then proposed what he was thinking. This would turn out to be fairly straight forward to develop into a PCB. The idea as too have the head and letters all in the same colour (the solder mask) and then have the area behind the eyes and around the letters free so that they blinking LED would shine through.

Draft2.png

I embellished this a bit further with my thoughts on where the components could be placed.

Draft3.png

Tag 2. Erstellen des Designs

Once I had KiCad available I proceeded to turn the SVG of the graphic into a PCB. To achieve this, the layer feature of Inkscape was invaluable.

Front-Cu.png The original image was exported as Front Copper (F.Cu). This will ensure that the section of the board that represents the head  and letters will be opaque and not letter any light through.
SolderMask.png The next layer to export as the solder mask. For the entire image was exported but this has to be converted to a negative since this defines where the solder mask should not go.
F.Mask.png This image is then taken into a graphics program such as GIMP or Krita and trimmed down as the entire outline for this design.
EdgeCut.png The last layer is based on the entire image and converted to an outline. This is then expanded using the Outset tool. This will ensure that milling tool following the edge cut will not conflict with the actual image outline.

Once the layers are exported and verified, the layout of the board can begin. First of all, a simple circuit is created to defined the required parts. We don't have a lot of time for this project to try things out. So I opted to have space for three LEDs thought I believe only two will be required.

Schematic.png

Screenshot 2024-10-21 at 19.11.53.png   Screenshot 2024-10-21 at 19.12.08.png

Screenshot 2024-10-21 at 19.19.32.png   Screenshot 2024-10-21 at 19.19.39.png

Tag 3. Montage und Prüfung

A week or so after uploading the design files to the fabricator, a panel arrived in the post. I had to assemble to see if there were any issues.

Example.png

The assembly is quite simple. I would recommend to solder the LEDs first. The battery holder is quite large and the LED pads are quite close. There is a risk of melting the battery holder if the soldering iron should touch it while soldering the LEDs.

The LEDs should be bent into place and the leads cut to length. Make sure to take note of the anode and cathode of the LED. These leads need to connect to the appropriate pad. If they are connected the wrong way, you will not damage the LED. It just won't glow.

After the LEDs are soldered in place, then the battery holder and switch can be placed on the board. Like the LEDs take note of the orientation of the battery holder. See the graphic below to see the correct orientation. Please ignore the white plus (+) marked on the board. The ⊕ marking on the battery holder should be bottom right as shown int he image.

The switch can be soldered in any arrangement but first the leads will need to be bent into shape so that they neatly touch their pads.

Note that for the battery holder and the switch you might need to apply more heat to get a good connection.

Bauteile
  • 3mm LED
  • 5mm LED
  • CR2032 Knopfzellhalter
  • Schalter

Front.JPG    image1.png

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