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Fabrication Prep and Bill of Materials!

A project log for SunLeaf

A solar powered wireless picopower sensor module with cloud Datalogging and control geared towards plant and environmental monitoring

AVR (lordKiCAD)AVR (lordKiCAD) 10/03/2016 at 22:120 Comments
Hello!! The new SunLeaf hardware is getting ready for fabrication finally after some more tweaking and preparation. So as for fabrication of the next revisions SunLeaf version 0.2a (a = alpha) the plan is to do another prototype run of 3-10 boards and hand assemble them testing desired functionality and noting fixes for future revs. At the same time I've been running the SunLeaf 0.2a through Macrofab's wonder fabrication platform. The goal of this new design is to get a hardware module that is working problem free with all our desired features functioning then to scale up and produce a pile of boards for beta testers and users !

So for the prototype run, we are currently evaluating fab house for quickturn manufacturing. I typically use OSHPark for all prototypes but as time keeps going by it might be cutting it close with their services. Either way I created renders of the new board with there fab:

Top View:

Bottom View:

The board is only about 2 dollars more expensive than the last revisions with an order total of around 47 dollars for a round of 3 from OSHPark. The necessary adjustments in size didn't hurt us on cost very much wihich is great.

Moving onto the bill of materials, everything for the prototype BOM comes from Digikey with the expception of the ESP-09 module that is ordered from a user on Tindie who imports them to the US. The BOM is simple it just explains the parts used, how much one costs in qty of one and the overall cost to build one SunLeaf. If you are feeling ambitious have at it, order some parts and boards and solder them up we'd love to hear about it. Anyways here is the BOM:

DesignatorMFR #Digikey#Cost (QTY 1)QuantityBuild Cost QTY
IC1ESP_09https://www.tindie.com/products/George/esp8266-esp-09-module/?pt=full_prod_search4.9814.98
FD3,FD2,FD1FIDUCIAL030
U2BQ24210DQCT296-28738-1-ND3.1913.19
U5PCA9518DBQR296-22764-1-ND1.9411.94
D1BAT20JFILM497-3381-1-ND0.4410.44
J11,J16,J9,J12,J13,J15,J14,J10,J8,J7,J6,J5B4B-PH-K-S(LF)(SN)455-1706-ND0.24122.88
D7,D6,D8,D9,D11,D12,D13,D10,D3,D5,D2,D4PESD3V3L2BT,215568-4041-1-ND0.47125.64
DA1ESDA6V1BC6497-6635-1-ND0.4210.42
Q2,Q1DMG2307L-7DMG2307L-7DICT-ND0.3820.76
X2ABS07-32.768KHZ-9-T535-9544-1-ND0.7710.77
X1ABM3B8.000MHZB2T535-9720-1-ND0.6610.66
D14RSB39VTE-17RSB39VTE-17CT-ND0.4510.45
J3B2B-PH-K-S(LF)(SN)455-1704-ND0.1710.17
J4B3B-PH-K-S(LF)(SN)455-1705-ND0.1910.19
T11909763-1A118077CT-ND0.5810.58
U474HC4052D568-1456-1-ND0.510.5
U1STM32F446RET6497-15376-ND8.5918.59
J120021121-00010C4LF609-3695-1-ND0.810.8
R42,R40,R3,R1RC1005F103CS1276-3431-1-ND0.140.4
H2,H1,H3M2.5_Hole30
R41,R39,R23,R18,R15,R14,R16,R26,R8,R6,R2,R11,R10RC1005F102CS1276-3430-1-ND0.1131.3
FB2MI0603K300R-10240-2373-1-ND0.110.1
SW1,SW2B3U-1000PSW1020CT-ND1.1822.36
P2CONN_01X0310
LED1LTST-C193TBKT-5A160-1827-1-ND0.4710.47
R37,R38ERA-3AEB3741VP3.74KDBCT-ND0.6321.26
R9,R20,R19,R17,R12,R21,R13RC1005F201CS1276-3959-1-ND0.170.7
R36,R35,R29,R30,R31,R28,R27,R33,R32,R34RC1005F472CS1276-3466-1-ND0.1101
R22RC1005F4870CS1276-3991-1-ND0.110.1
R4,R5CPF0402B22RE1A102720CT-ND0.5621.12
R7RC1005J473CS1276-4416-1-ND0.110.1
C4,C6,C14,C8,C10,C15,C3,C9,C1,C22,C27,C7,C17,C18CL05B104JP5NNNC1276-1506-1-ND0.1141.4
C11,C12CL05C180GB5NCNC1276-1647-1-ND0.120.2
C13CL05A475KQ5NRNC1276-1481-1-ND0.3610.36
C2,C5CL05C090CB5NNNC1276-1616-1-ND0.120.2
FB1BLM15HG601SN1D490-3998-1-ND0.2310.23
P1CONN_01X0410
C21CL10A106KQ8NNNC1276-1038-1-ND0.2410.24
C20,C19CL05A105KA5NQNC1276-1445-1-ND0.2420.48
LED2LTST-C191KGKT160-1446-1-ND0.2910.29
LED3LTST-C191KFKT160-1445-1-ND0.2710.27
U3AZ1117CR-3.3TRG1AZ1117CR-3.3TRG1DICT-ND0.4110.41
J2475890001WM17143CT-ND0.8110.81
R24,R25RC1608J202CS1276-5069-1-ND0.120.2
PCB CostOSHPark (3 Boards)48.216.116.1
BOM Total Cost63.06

If you wish to view it as a google spreadsheet the following link will do just that: https://docs.google.com/spreadsheets/d/1kv7WRCuP9jof3ieIvjWm7yBUWpwseHQou-YMSgxwjEM/edit?usp=sharing

So there we are, we have a new board a BOM, and prepping to order, just some more final checks. That's all for now, but expect more posts this week!

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