That being said, I noticed the slots you’re using for the battery on the main board are set to finish at 0.010”. Most PCB suppliers won’t have a slot-drill smaller than 0.020”, and those that do, don’t like using them on 0.062” thick boards. (Saturn has a 0.016” slot drill, but they break frequently). See if you can get that up to 0.020” finished, that will allow for a 0.025” slot drill, they’re more common. It’s OK to just send us a new BoM. Do you have any specific dielectric spacings for the 8 layer stack-up? The existing one has one gap at 12.6 mils for some reason. Let me know and I’ll do up a stack-up for you. Thanks, Steve Pre-Production Engineer From: Rick Sent: Wednesday, December 09, 2015 2:43 PM To: Steven Cc: Bob; Crystal Subject: Hybra Sound Band 5.1 and Flex Circuit files Hi Steve, Attached are the files I went over with Bob yesterday. FWIIW I just verified with my design software that the PCAD ASCII exports for each board are actually ASCII :-) I Cc’d Crystal and Bob to keep them in the loop and it is my goal that you should have files suitable for quoting after this round of picking your brain :-) FWIIW the flex circuit now has: * all of the push button pads connected with traces per your and Bob’s suggestion * all vias are 20 mils with 10 mil holes * all of the pads on the main connector enlarged per your email * traces re-routed away from the connector pads at right angles to provide clearance * 8&8 minimum width and spacing design rules * silkscreen is not to be printed on flex circuit; it is provided for parts placement info. Questions: * Can you overlay one source file or Gerber on top of the other to make sure that the Battery mounting slots on the Sound Band 5.1 PCB line up correctly with the corresponding slots in the flex circuit? * Can you provide me with your existing BOM for the Sound Band 5 so I may add parts directly to your XL spreadsheet? * Can you please look at the XL spread sheet in the Sound Band folder and suggest appropriate values to make it an .062” board (or thereabouts). Caveats: * You did not get to kibitz the original Sound Band (5.0) layout and I would appreciate your input on *anything*. * It is routed at 6&5 design rules with 12 mil vias and 6 mil holes. I will enlarge both on the subsequent (5.2) release but will leave them alone for now. * I believe that I correctly carved out a “Keep Out” area under the antenna for the wireless module on the board, but would like your confirmation I did not screw it up. * I also enlarged the main connector pads on Sound Band 5.1 to match the corresponding attachment points on the Flex Circuit, anticipating your suggestion there as well. Many thanks, Rick
We are pleased to announce the last of the long lead time components have arrived. The AKM piezo driver reels, an 18 week lead time part, showed-up Thursday last week. For anyone who is not familiar with micro-electronic assembly, in most cases, mass chip placement uses pick and place machines, to set all the components on a printed circuit board. These pick and place machines use reels to organize the parts and ensure very high speed loading. The reels in the photos below contain 3000 piezo driver chips. All the SoundBand part reels contain between 1500 and 5000 parts.
With the drivers and the other parts here, we immediately approved the build and assembly of 25 completed production grade SoundBands.
Since all of the component procurement/storage, board build, flex strip build, electrical assembly, electrical component testing, and final assembly/test is performed at a single site, we can closely monitor all aspects of the build and minimize defects.
From this point forward we will update as important milestones are reached. In the coming weeks each day will be touch and go, but we hope to steady the ramp, after the first 25, in quantities of 200 very soon, then increase to 400 unit batches until all the Kickstarter units are delivered. We will keep everyone informed at each step and continue to provide high quality images of the process.
Also please keep a look-out for a new survey that will help us verify the finish color you want.
As always, we thank everyone for your continued interest and support. Sincerely, we look forward to delivering your reward as soon as possible.
We are happy to share the final board we send out for build. You will notice a few changes. In the center left of the board rests the new solder points for the integrated flex strip. If you remember from previous updates we eliminated the over-molded wiring attaching the earpiece to dongle and designed a waterproof flex circuit. This flex circuit solders to the board at this point. This significantly improves the strength of the connection between the dongle and earpiece and, since the flex strip sandwiches between the main board and battery, further reduces the overall dongle body thickness. Additionally, this flex circuit requires no over-molding and has a really cool look and feel, since it is so thin and flexible. Also you will notice on the left end of the board an integrated battery solder connection. This allows us to eliminate any wiring between the battery and board and solder the battery directly. This reduces thickness and length of the dongle and allows for automated solder of both the battery and the flex strip in one operation. We will keep updating as parts go out and provide photos of the completed parts and final assembly of the first batch very soon.
With all the feedback and our final thoughts in the design we have now finalized all aspects of SB. The main board, housings, flex connector between the dongle and earpieces, and all weatherproofing has been completed. We are pleased to share the final design we will take to manufacturing. Now that the design files are completed we have begun building all aspects of the band. We will share photos of each component and the assembly process as we go through each stage in the coming month. We are very excited to have hit our stated timeline and look forward to getting the units out as soon as we can. We will provide a batched delivery timeline in the middle of August. Nearly all backers have updated their address, but If you have not updated please do so this month. If we do not hear back by the end of August then our customer support team will begin reaching out to you using the current information we have.