Prototyping PCB using Laser Galvo from SLA 3D printer

The main problem with X/Y Cartesian table or Delta type CNC machines is the non-continuous exposure approach i.e.  the back and forth movement with deceleration / acceleration at each end of the strike. 

Even vector laser exposing i.e. similar to isolation milling uses 5-10 traces at 0.1 step width is not the best solution;. Nevertheless,  it still seemed a lot quicker than milling without the noise and dust. 

Even though it works we didn't believe this was the most optimum approach. We therefore looked at the approach taken by SLA printers using laser + polygon mirrors creating a continuous beam across the full length of the PCB. On the step down is required. the other approach we looked at was full image exposure using an LCD and DLP type beamer which gave excellent results and was much quicker. 


The results are not complete yet but we are collecting information here in a rather jumbled manner until we get some time to sort it out.



Microcontroller:
  • http://www.ichaus.de/

Alternative "rotary" laser beam 
  • https://www.youtube.com/watch?v=8ekioGZOkb4
The laser is spun/rotated creating an arc across the PCB surface (similar concept to the propeller clocks). slavkok68 created a python arc raster converter,  as the shape of the beam was in a form of an arc rather than a line. The specs:
  • Laser 20mW/405nm. Rotation diameter 200mm speed 480 RPM.
  • Every rotation PCB advance by 0.01mm.
  • LinuxCNC is used to do near all yob, raster data is provided by python script.
  • In other test 4mil trace and 4mil track (spiraled to length in about 200mm) was succesful


Laser beam 
  • Galvo Laser direct on Thermal Paper
    • https://www.youtube.com/watch?v=7nVMRmfJnZg
    • https://www.mikrocontroller.net/topic/306825?page=2#3843677
  • https://www.youtube.com/watch?v=iYI5aCICtwk

3D Printing onto PCB
  • https://3dprint.com/11367/3d-print-copper-circuit-board/ 
  • http://3dprintboard.com/showthread.php?5077-3D-Printer-Etches-Copper-Circuit-Board

Direct UV exposure onto PVB using LCD Display on Photopolymer resin (SLA Concept)
  • https://www.youtube.com/watch?v=vxl7glJMKOQ

Laser Projector
  • https://www.youtube.com/watch?v=Dp2YlRDnHF0&spfreload=10
  • https://www.youtube.com/watch?v=9IgcRLsuwmQ
  • https://www.youtube.com/watch?v=sIV0icM_Ujo
  • https://www.youtube.com/watch?v=j7qieOBLpMM
  • https://www.youtube.com/watch?v=6xU5cn1ARMg (Postive)
  • https://www.youtube.com/watch?v=bLnAJ-mSElE (Pic and place)
  • https://www.youtube.com/watch?v=TrmQFqIotYM
SLA Laser Galvo, Shields, Light Engines
  • https://www.youtube.com/watch?v=dZYVda4fC4k - Exactly!
  • https://www.youtube.com/watch?v=ti82mfp0fDY
  • https://www.youtube.com/watch?v=7nVMRmfJnZg
    • http://stackoverflow.com/questions/6199636/formulas-for-barrel-pincushion-distortion
  • https://www.youtube.com/watch?v=UwrChchSOUA
    • https://github.com/tscha70/3DPrinterSTLFiles/tree/master/LaserShow/laser4
  • https://www.youtube.com/watch?v=vGYbbFLWTGU
  • https://www.youtube.com/watch?v=EKatZzg83mI
  • http://www.ebay.com/itm/20Kpps-HightSpeed-galvo-scanner-for-laser-lighting-NEW-Without-Show-Card-/221204811926?hash=item3380d59096:g:BAEAAMXQhpdRzoaF
  • https://www.youtube.com/watch?v=Ttv1Lo1Ld2o
  • https://www.youtube.com/watch?v=GhJ-v6k1gPw
  • https://www.youtube.com/watch?v=MUtxg7VziGE
  • https://www.youtube.com/watch?v=vvbzIy2U1J0
  • https://www.youtube.com/watch?v=MsaYcX5aIac&t=11s
  • Galvo Laser of UV sensitive PCB
    • https://www.youtube.com/watch?v=UfHwvNbRenk
Direct Ink Jet printing
  • https://www.youtube.com/watch?v=_DGUUoK_XTA
    • using:
    • Epson Stylus Photo R800
    • Reset-chip mod - you can ignore empty-ink warnings
    • All ink cartridges except for the black ones are empty
    • Special heat-drying ink for use as etch resist (Tritron N-GEN XN 00070 Black, Info)
    • Primer (PPA5, CATS+)
      • PPA5 is 95% Ethanol with some chemicals to make the ink stick.
      • Primers are made specifically for Tritron ink.
      • Alternatively use a mix of Ethanol with a pinch of Glycerin.
        • Adjust workflow: do not swipe but dab alternative primer onto board.
    • http://shackspace.de/wiki/doku.php?id=project:beta-layout:pcbprinter

LCD Shield Screen Test
  • http://ceezblog.info/2015/04/20/240x320-28-tft-shield-driver-4535-for-arduino    
  • http://www.mcufriend.com/down/class/?6.html

UV resist preparation for other use
  • https://www.youtube.com/watch?v=dCOgEEGkR4Q
Refs:
Resin Suppliers
  • https://www.just3dp.com
  • http://www.venuscreator.com/spot-laser-module-for-uv-resin.html
PCB Apps
  • https://circuitmaker.com/
    • https://www.minds.com/blog/view/551766770508115968
Direct inkjet etch resist printing
  • http://techref.massmind.org/techref/pcb/etch/directinkjetresist.htm
  • http://www.sxlist.com/techref/pcb/etch/cx4200-vs.htm
    • Refill: http://www.eddiem.com/photo/printer/chipreset/resetchip.html

3D Printing conductive inks

this kick-start prints two chemicals on top of each other which react to form a conductive track:
  • https://www.kickstarter.com/projects/cartesianco/the-ex1-rapid-3d-printing-of-circuit-boards

Prototyping  Services
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