Build your own PC board: a designer's dream

LPKF's ProtoMat S62 desktop milling machine exceeds designer expectations with its mini learning curve coupled with low cost and fast turnaround.

The desktop S62 is a 3D milling machine designed to create printed circuit boards (PCBs). Its 10-tool autochanger enables it to handle a wide range of jobs (see figure). The plotter's milling head travels at 150 mm/s, and the high-performance spindle motor ratchets up to 62,000 rpm. Also, its Z-axis movement permits depth in RF designs as well as very flexible modifications to non-PCB materials (such as covers, photo masks and labels).

Thanks to their competitive price tag, units can find homes in organisations that couldn't afford this type of technology in the past.

Why is it so popular?

Many users cite the unit's fast turnaround as its key advantage. This feature had a major impact on numerous design aspects because it's now possible to crank out a new design as it's developed. The S62 also makes incremental changes, fixes or enhancements practical. Test, debug, refine can now be the mantra for both board development and software.

The ability to quickly create a single board means that developers can verify their design before making additional boards. This avoids wasted boards when a major design defect is found. Even minor fixes can be easily accommodated.

When it comes to media, many designers are starting to appreciate flexibility. The S62 can cut photo masks, pockets in microwave boards, covers for boxes (including holes for sockets) and much more.

Most S62 users are experimenting with these features, which can enable them to create customised boards and boxes for individual projects. This is in contrast to PCB houses, which are set up to make dozens of identical boards per run. These houses still play a part for many S62 users because they do excel in volume production compared to the S62. You won't make thousands of identical boards with the S62, but a dozen or more is well within the in-house breakeven point.

Playing it close to the vest

In-house PCB creation isn't new. But it was never cleaner and as inexpensive as with the S62. Moreover, developers can keep control of a design. The CIA and NSA aren't the only organisations that will restrict access to a board.

Proprietary intellectual property (IP) is often the centerpiece of a company's product design, and this is often embodied in the PCB. The S62 simplifies security management because physical security is typical within this workplace.

The S62 also has other implications when combined with the fiducial recognition camera used for repeated operations on a PCB or other material. The ability to add more circuitry to an existing board enables delivery of custom boards, depending on the application and buyer. A supply of partially configured boards can be updated easily using the S62. Likewise, a board consumer could use an S62 to add circuitry to a virgin part of a PCB.

Easier than it looks?

S62 users discover that there's a short learning curve. Not even sophisticated and very compact designs can hold back novices. If the PCB design software can generate it, then the S62 is usually able to comply.

Developers can push the size limits of their design because there's little cost to trying out a design. A newer, more compact design only requires a PCB design change and a new board from the S62.

Because operating the S62 requires minimal training, virtually anyone can handle the job of actually setting up and running the unit. Of course, developers love to get their hands on it because they don't have to wait for someone else to configure the system. Unfortunately, they often must wait in line due to the unit's popularity among other groups within their own organisation. Luckily, it's easy to hide the S62. It's self-contained, small and quiet. Just attach a PC via a USB cable to drive it.

Milling PCBs isn't new. Units that are larger and more expensive than the S62 have been available for years, many from LPKF. But the price, size and ease of use cause S62 users to make a quantum leap to change how they design and what designs they can consider.

The ProtoMat S62 has proved to be extremely popular. However, you can be on the lookout for another unit from LPKF Laser and Electronics - the less expensive S42 forgoes the tool auto-changer, which isn't always required.

This article appears by permission. Originally appeared in Electronic Design. © Penton Media.