JF Brandon Co-Founder, VP Sales and Marketing BotFactory A New Approach to Additive Manufacturing sme.org/smartmfgseries
A New Approach to Additive Manufacturing sme.org/smartmfgseries
Small run complexity PCB Manufacturing Complexity Small run complexity Mass production complexity Copper rods on wood Charles Ducas: circuit printing Paul Eisler: etching Hazeltyne: Multi-layer IBM: SMT High density pincount SMT 1900 1925 1950 1961 1970 1980
Prototyping electronics is LONG, HARD, & EXPENSIVE 1-2 weeks 6x the price for 24hours $250 for rigid PCBs $1500+ for flexible PCBs Multiple iterations required Mistakes are expensive!
Great products, small beginnings 1891 - started in an EMPTY WAREHOUSE 1905 - started in a GARAGE 1946 - started in a RADIO REPAIR SHOP 1976 - started in a GARAGE 2010 - started in a GARAGE *Pictures credits at the end of the presentation
Small runs = different needs Quick turnaround Low operation cost Prototype quality Accessibility in-house or nearby Streamlined process Encouraging experimentation Milling machines Manual etching
Squink a desktop electronic circuit factory Reduce cost to around $5 per circuit Reduce manufacturing time to between 30min 2hours per circuit (depending on the circuit) All-in-one solution Print traces and insulating layers ( Multilayer ) Place solder paste or glue Pick and Place components Intuitive operation Keep your IP in-house
Typical Users Professional Engineers + + Iterate PCB designs more often Reduce their product time-to-market R&D labs at tech firms, established small-to-medium sized businesses, hardware start-ups I have a business making modern fuel injection computers for automobiles and assorted accessories. I use Squink to rapid prototype new helper board designs and likely for pick and place on prototypes and first run manufactured boards. -Kickstarter Backer Jason Russell, vems.com Finding the next market hit requires a lot of experimentation
Typical Users Academia + + + + Accelerate research Innovate with new materials and processes Improve their Makerspace Teach students how to build electronic boards Found in schools with a technical curriculum Setting up our @BotFactoryNYC #Squink printer for @MusEDLab #prototyping #conductive #ink #paper #music #interface #designs -Our first customer, Alex Ruthmann, PhD, NYU MusEDLab Publishing papers is Academia jargon for beating competitors to market Hands on education is more effective
Typical Users Makers/Hobbyists I'm a retired software and hardware engineer, and I'm planning on doing some serious puttering :) I own a small farm, and I have a long list of automation projects that will require custom circuitry. For example, a spring depth and flow gauge. I have a long list of things like this -Kickstarter Backer Tom Dilatush, Paradise, UT It s all about trying new ideas
Three steps, Many challenges Printing Solder paste / Conductive epoxy Picking and placing
Printing traces the right way Lines have to be smooth, flat and conductive. Extrusion is hard to control thick ink = lumps thin ink = spreads easily Inkjet YES, but: Beware of spraying and opens Tune ink adherence to substrate Handle nozzle clogging and breaking Circuit overprinted 25 times
Multi-layered boards and vias Inkjet printing a multilayered board Using insulating patches analyze copper layers to find intersections Using insulating layers use drill files for vias Challenges Controlled dielectric and impedance Flat surface New materials sometimes = new deposition or curing method Additional layers
Solder paste / Conductive epoxy Extrusion challenges Air gaps Variations in material density Paste adhesion used in PnP Conductive epoxy No/lower heat required No capillary realignment Optimal dot size high adhesion limited smudge
Picking and placing Reels vs Tray Similar parts? Polarity? Tray needs ergonomics Use cut tapes for two-pin parts Guide the user on part orientation Tolerances = placement errors Machine vision counters most errors Speed vs convenience Preparation Process Handling numerous package sizes
User interaction Complex systems need a simple interface Automation principle Assume users don t know what they are doing Clear instructions, no manual Offer a realistic preview of the result K.I.S.S.
Where is BotFactory going?
Structural / non-structural Non-structural: Standard board encased Structural: Circuits printed ON the casing Circuits ARE the casing New material = new applications (plastic, packaging material, acrylic )
Flexible, thin and lightweight FR4 = 75% of the weight of a PCB Lightweight, flexible circuits (eg, on Kapton) have many applications Avionics Wearables IoT Circuit adapts to different shapes Tubular devices or sensors Utility services / Oil industry Canned food sensors Wrapping sensors Bullet proof vests Ceramic insulation breaks
Experimentation Break free of traditional manufacturing constraints Low cost of prototype manufacturing, ultra-fast turn around time Multi-substrate: Paper, Plastics, Acrylics, FR4, Kapton Multi-layer printing Attach components to solder-able / nonsolder-able materials Improved, highly conductive ink
Thank you For more information, contact JF Brandon, Co-Founder, VP Sales & Marketing Jf.brandon@botfactory.co www.botfactory.co
Credits Philips logo and picture: http://www.philips.com/about/company/history/ourheritage/index.page HP logo and picture: http://en.wikipedia.org/wiki/hewlett-packard Sony founders: http://www.telegraph.co.uk/technology/technology-companies/8578093/ibm-turns-100-other-surprisingly-ancienttechnology-companies.html?image=2 Apple founders in garage: http://www.bbc.co.uk/news/business-14659843 Origami birds: http://www.rsc.org/chemistryworld/2013/05/origami-electronics-nanopaper-silver-nanowire-ink-foldable-antennas