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An Unfortunate SMD Project

If you like happy, easy to build projects, this is not for you. This project is only for people who like to be miserable and frustrated.

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Test your surface mount soldering skills out, starting with a 1206 package and work your way down into an oblivion of frustration. Powered by a CR2032 coin cell and Attiny 85 SOIC.

Be warned that trying to hand solder a 0201 package, which is just slightly larger than a grain of sand, may be considered evidence of insanity and get you committed to bad places by your loved ones and/or arch nemesis.

Making LEDs blink is what people think make Makers happy, but they are wrong. Makers want to be miserable. They like to make mistakes and to have to try things over and over again. That which does not kill us, makes us stronger. This project will make you strong!

Hand soldering a 1206 is easy and makes me happy, so I decided to see how far down the package sizes I could go before I was reduced to tears. I can do a 0402 package by hand, but it isn't pretty.

My biggest hurdle was determining orientation of the LEDs. You need to refer to the datasheets because each one has different markings. You will also need a USB microscope or really good magnifying glass for the smaller packages.

You are also going to need a good set of tweezers. Robots, who will rule us shortly, have no trouble picking and placing these devices (without error or complaint I might add), but shaky hands and faulty eyes make this a sad affair all around for us miserable mortals. If your luck is as bad as mine, you will spend lots of time frustratedly looking for microscopic dots when they fling out of your tweezers. Buy several extras of each size because the universe will go out of its way to make sure you will need them.

SMD_challenge.png

Schematic for those of you depressed enough to be interested.

Portable Network Graphics (PNG) - 88.86 kB - 06/05/2017 at 03:31

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SMD_challenge.ino

Arduino sketch for anyone unfortunate enought to want to make LEDs blink.

ino - 3.41 kB - 06/05/2017 at 03:17

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  • Programming Surface Mounted Chips

    MakersBox06/14/2017 at 02:59 1 comment

    A majority of my projects to date have used DIP package Attiny85, 84, and Atmega328. These are usually programmed beforehand using a ISP shield on an Arduino, or afterwards using the ISP header. My first PCB design, was in fact, a shield which could be used to program the variety of AVR chips I was using. Breadboarding up an Arduino-as-ISP circuit time every time I needed one was error-prone and frustrating.

    Programming via ISP header using Pogo Pins

    My Making has progressed to the point that I have started doing SMT, mainly because I've been doing wearables and like the idea of having a coin cell battery on one side and the microcontroller on the other in a nice tidy package. The SOIC package is hand solderable, and using pads for the ISP header instead of through holes helps maintain the advantage of going SMT. Making a good connection to pads using a 2x3 pin header was a hit-and-miss proposition, so I was happy to find Nick Sayer's ISP Pogo Adapter.

    SOIC to DIP adapter installed in a ZIF socket: Turtles all the way down . . ..

    It occurred to me that since not all projects have ISP headers, there should be some way to program the chips prior to installation. With a little googling, I found SOIC to DIP adapters which can be used to mate up with a DIP ZIF fixture. A SOIC 20 allows me to program the AVR 8-pin, 14-pin, and 20-pin packages!

    EIAJ Flavor SOIC. Datasheets are your friend . . .

    The one cavat here is to be aware that there are two types of SOIC package, a wider EIAJ version that AVR supplies, and a narrower JEDEC version (oh, why do they do this to us?). My first ebay adapter purchase was the narrow version, and this problem has bit me with PCB footprints as well. A word to the wise . . .

  • The smallest part I have ever worked with . . .

    MakersBox06/06/2017 at 02:32 5 comments

    This is my forth iteration of this project. I don't know why I punish myself.

    The smaller LEDs are hard to tell the orientation. They are all packaged in the same orientation with the negative side (cathode) toward the side of the tape with holes in it. They all have a "whisker" wire that point to the positive side (right in the photos).

    I must confess, I never even tried to hand solder the 0201 chips. I can do the 0402s by hand, but even with the thinnest of tips, I doubt you can get the 0201s to stick without cooking them. Prove me wrong.

    Here is my first attempt with a solder mask and hot plate. I had to pull the LED off with the iron (it basically disappeared into the solder on the tip), and then remask it. Quite frankly I'm surprised it worked. At least I proved the circuit. Now I can move on to something less unfortunate.

View all 2 project logs

  • 1
    Step 1

    You should not build this. It is impossible to complete, so why bother. The picture is probably photoshoped to show it working, as is this video:

  • 2
    Step 2

    If you want pain in your life, do not read the datasheets. They contain very sad information. The pictures are also miserable. You have a 50-50 chance of getting the alignment right, so why even try?

  • 3
    Step 3

    Soldering by hand is impossible, so don't even try. It will only make you rant. It is unlikely that this video will help either:

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Discussions

Yann Guidon / YGDES wrote 06/16/2017 at 21:52 point

Rename this as "Badge of Horror" and they'll sell like hot cakes during hackerfests and faires !

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oshpark wrote 06/17/2017 at 06:35 point

Nice name!

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zakqwy wrote 06/09/2017 at 14:47 point

Gah, 0201! I picked up a handful of those Kingbright LEDs (in yellow rather than blue) and was able to reflow a few in my toaster, but they are a real pain to deal with. 

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K.C. Lee wrote 06/09/2017 at 11:19 point

Should try to pack the layout to really pack these parts tight and/or use them on the worse solder mask alignment from some cheap Chinese PCB board house.  
Now that would be a better challenge. :)

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MakersBox wrote 06/09/2017 at 14:37 point

Oh, the missery . . .

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Yann Guidon / YGDES wrote 06/09/2017 at 18:12 point

Do you speak from experience ?....

Because you sound like you speak from experience.

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Yann Guidon / YGDES wrote 06/09/2017 at 08:44 point

Next version: introducing 01005

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Yann Guidon / YGDES wrote 06/09/2017 at 08:44 point

How do you even get 0201 parts ?

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MakersBox wrote 06/09/2017 at 15:42 point

Links in the BOM.

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Yann Guidon / YGDES wrote 06/06/2017 at 23:52 point

OK so when do you sell kits ?

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MakersBox wrote 06/07/2017 at 05:40 point

This project has made me miserable enough without profiting off other unfortunate, misguided Makers.  You should be paying me not to post this type of project!

Although, if you do want to throw away your money, I sell kits for other, less unfortunate projects at https://www.tindie.com/stores/MakersBox/.

P.S., I've provided everything you need to do this yourself in the BOM.  The boards would only be $6 for three, and the rest would be about $10.  Small price to pay for the frustration of a life-time (or the ultimate bragging rights if you accomplish the impossible).

P.P.S. Oh, wait. You still have to program the chip.  Will the misery never end?  Maybe I should just sell programmed chips.  No tech support though. You'd only have yourself to commiserate with.

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Yann Guidon / YGDES wrote 06/17/2017 at 11:53 point

Yes, please sell programmed chips. The misery should only be about soldering, not dealing with software etc...

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oshpark wrote 06/06/2017 at 20:34 point

What adapter do you use to program the AVR?

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MakersBox wrote 06/06/2017 at 21:26 point

I'll have to do a post on that, but the short answer is using an Arduino and an ISP shield (https://www.tindie.com/products/MakersBox/yet-another-programming-shield/) and either a SOIC adapter to program the chip before soldering, or a pogo adapter (https://www.tindie.com/products/nsayer/avr-isp-pogo-adapter-kit/) to connect with the ISP pads on the PCB after the chip is soldered.  It is easier than it sounds.  Both tools mentioned are Purple!

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oshpark wrote 06/06/2017 at 22:38 point

Awesome, thanks

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mwahid wrote 06/05/2017 at 06:27 point

Cool project :)

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oshpark wrote 06/05/2017 at 05:08 point

clever idea! looks fun :)

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