PCB Milling

I'm making photodiode (transmipedance) amplifiers, and here is the first PCB being milled today. In the foreground a test-run where the cutter-height was too low resulting in too thin or vanishing PCB-traces. Note how the PCB material is not held in place along the Z-axis at all. The PCB-blank is just located in X/Y on the table using two locating pins/holes. In the Z-direction the idea is that the pneumatic cylinder pushes the lower flange of the spindle into contact with the PCB-material, and the exact cutter-height is adjusted relative to this flange only.

The toolchain is (old!) commercial software: PADS PowerLogic for schematic design, PADS PowerPCB for PCB-design, CircuitCam for converting the gerbers to HPGL, which BoardMaster uses to drive the mill (over RS232).

pd_amp_pcb_top pd_amp_pcb_bottom

For general purpose 3D CAD at work we have Vertex (a Finnish Inventor/SolidWorks clone) and I used it to draw a model of the amplifier:
pd_amp_assembly pd_amp_exploded

The size of the PCB and enclosure is mostly limited by how much of the powersupply one wants on-board, and how big connectors one wants to use. I'm using a standard BNC connector (SMA would have been smaller). The board is powered by a +9...18VDC supply which is DC2DC converted into +/-12 V and then regulated to +/- 5 V for the op-amp circuit. The box at the front is an RF shield for the amplifier itself. Light enters through an 8 mm hole in the face-plate and hits a TO-18 mounted photodiode. More on the circuit later.

The enclosure is 48 mm in diameter with a 16 mm thick face-plate, a 4 mm thick back-plate, and the body (55 mm length) bored out to an inner-diameter of 34 mm. The body should fit a 25x54mm PCB. The end-plates are attached to the body with five M3 screws on a 40 mm diameter bolt-circle. There is an M6 thread on the bottom of the face-plate, for attaching the amplifier to an optical-table or other instrumentation. I made two of these from 50 mm aluminium round-bar on a manual lathe and mill (using a rotary table for the holes/threads).


Note: for manual machining five evenly spaced holes the angle-sequence is: 0 - 72 - 144 - 216 - 288 - 0.

I'm thinking about polishing these a bit and then anodizing them. But for RF-shielding the contact-surfaces of all three parts would then have to be sanded/milled-down after andoizing. to ensure good electrical conductivity between the parts.

Thursday manual milling

I made this ca 78x48x31 mm mount for a Faraday Isolator (Model IO-7-633 Optics For Research, now sold by Thorlabs) from 50x50 Aluminium bar on the manual mill at work. It raises the isolator up from the table by 31 mm. The isolator is attached to the mount with two M6 screws, 28 mm apart. The cap-head screws are countersunk so they don't protrude from the bottom. This mount is clamped to the optical table using the 8x5 mm slots in the sides.