Homebrew PCBs

Stefan Trethan wrote:

> It appears much easier, IMO, to just buy a big spool of thin wire, and  
> thread it through all vias in a board (in one piece). then solder, then  
> cut the crisscross pieces away. I think the CNC would be more work.

   Yeah for 1 or 2 maybe, but try doing about 10 or 20 per board.  Punch a 
button, go away, and come back and they're all done is way easier.  You'll 
easily make up the difference with a machine in no time.  Get it reliable and 
50+ via tight boards may not even be a problem..  Real work is locating the 
right holes in a dense board, that's why the CNC would be such a boon doing it 
by itself from the drill file.

> 
> Maybe it is practical to make small studs of copper, just a bit longer  
> than the hole. Place the board on spacers to allow the studs to protrude  
> maybe 0.5mm or less, above a steel plate. then take a hammer and hammer on  
> the board, so that the studs are riveted in place.
> 

   There are some like that, with more of a press than a hammer.  Still easier 
to not be there, I'd want to CNC even this method.  But thin wire needing only a 
slight bend and light cut would be easier still, doesn't even need the studs or 
press.  Especially good when you can drill the board with the same machine.  I 
rarely drill or via, doing SMT and wire jumpers on single sided for ease.  But a 
decent automated via machine would bring them back into play.  Still easier to 
not have 2 sides to align, but it'd be worth it sometimes.

   While I have a full gantry CNC system, a simple seperated XY slide 
arrangement for the PC board would be easier for most to build.  I'm going to 
play around a bit and see about the simplest design I can come up with, it may 
be very practical.

   But after a trip to the store for some Reynold's paper.  Should have thought 
of that myself, not like I haven't used it before and noticed how good it was at 
non-stick cooking.  But wasn't doing boards at that time so didn't put 2 and 2 
together.

Alan