KiCad: Generate and finalize PCB file

.gitignore

@@ -22,3 +22,15 @@ dist
 
 # Ergogen
 /ergogen/output
+
+# Kicad temporary files
+/kicad/*-backups/
+*.bak
+*.kicad_pcb-bak
+*.kicad_sch-bak
+*.kicad_prl
+*-save.pro
+*-save.kicad_pcb
+~*.lck
+_autosave-*
+fp-info-cache

README.md

@@ -4,17 +4,92 @@ Custom ergonomic mechanical keyboard with low-profile (Choc) switches.
 
 ## Repository structure
 
-- `/layouts`: Keyboard layouts created with the [Keyboard Layout Editor](http://www.keyboard-layout-editor.com) 
+- `/layouts`: Keyboard layouts created with the [Keyboard Layout Editor](http://www.keyboard-layout-editor.com)
 - `/ergogen`: [Ergogen](https://docs.ergogen.xyz/) files to generate outlines, cases and PCBs
+- `/kicad`: KiCad PCBs and generated files
+- `/3d_prints`: 3D models for the enclosure
+- `/qmk_keyboards`: [QMK](https://qmk.fm/) keyboard files to compile and flash the QMK firmware
+
+## How-to
+
+### Generating the PCB
+
+The KiCad PCB files are generated using Ergogen. Then they need to be manually routed and finalized in KiCad before
+they can be exported as Gerber files and send to a PCB manufacturer.
+
+#### Generating KiCad files with Ergogen
+
+To generate the KiCad PCB file with Ergogen, first install Ergogen using npm: `npm install`.
+
+Then, run `npm run ergogen`. You can find the KiCad file in `ergogen/output/pcbs/eepyboard.kicad_pcb`.
+Copy the file to `kicad/eepyboard.kicad_pcb`.
+
+#### Routing and finalizing the KiCad files
+
+Open the file in KiCad (create a project if non exists yet). Finalize the PCB in KiCad.
+
+1. Run the Design Rules Checker. Check the errors. Most of them can be ignored/excluded.
+    - All "Footprint not found in libraries" can be ignored completely. This is due to how Ergogen generates the PCB.
+2. Add VCC and GND planes.
+    - Menu: `File -> Board Setup`
+    - On "Physical Stackup", change the copper layer number to 4.
+    - On "Board Editor Layers", change the type of `In1.Cu` and `In2.Cu` to "power plane".
+    - NOTE: `In1.Cu` will be the VCC plane, `In2.Cu` will be a GND plane.
+3. Add filled zones to the VCC and GND planes.
+    - Select the `In1.Cu` layer.
+    - Use the "Add a filled zone" tool and draw a rectangle that contains the entire board. Assign the zone to VCC.
+    - Repeat the same process for the `In2.Cu` layer and assign the zone to GND.
+    - The zones don't need to be filled just yet.
+4. Add another filled zone on the `B.Cu` layer and assign it to GND.
+5. Route all signal traces (no VCC or GND yet). Recommended order:
+    - Matrix rows (on `B.Cu`)
+    - Matrix columns (with vias on `F.Cu`)
+    - NeoPixel data pins
+    - Connect everything to the MCU.
+6. Route VCC traces.
+    - Connect the VCC traces between the NeoPixel chips and the capacitors with a 0.750 mm track.
+    - Place free-standing vias (Ctrl+Shift+V) in the middle of the just created VCC traces.
+7. Route GND traces.
+    - Draw short GND traces with a 0.750 mm track and a via at the end next to the GND pads of the NeoPixel chips.
+8. Fill all zones by pressing B. Make sure that all nets are routed.
+9. Run the Design Rules Checker and make sure there are no (relevant) violations.
+
+#### Export Gerber files
+
+Now you can generate the gerber, drill and map files.
+
+1. Generate Gerber files.
+    - Menu: `File -> Fabrication Output -> Gerbers`
+    - Select plot format `Gerber`.
+    - Set output directory to `gerber/rev1/` (adjust for current revision).
+    - Set coordinate format to `4.6, unit mm`.
+    - Click `Plot` to generate files.
+2. Generate drill and map files.
+    - In the previous dialog, click `Generate Drill Files...`.
+    - Set drill file format to `Excellon`.
+    - Set drill units to millimeters.
+    - Set same output directory as above.
+    - Click `Generate Drill File`, then `Generate Map File`
+3. Create zip file with all generated files from `kicad/gerber/{REVISION}`.
+    - No subdirectories, only files.
+    - Ideally name the file `eepyboard_{REVISION}.zip`.
+4. Upload zip file to manufacturer and make sure everything is correct.
+5. Add all generated files to version control (the zip should be on gitignore).
+
+### Compile and flash QMK firmware
+
+TODO: Add this when building the firmware
 
 ## Used software
 
 - [Keyboard Layout Editor](http://www.keyboard-layout-editor.com)
-- [Ergogen](https://docs.ergogen.xyz/), [unofficial Ergogen web UI](https://ergogen.cache.works/)
+- [Ergogen](https://docs.ergogen.xyz/), [unofficial Ergogen web UI](https://ergogen.ceoloide.com/)
 - [KiCad](https://www.kicad.org/)
-- [FreeCAD](https://www.freecad.org/)
+- [Onshape](https://www.onshape.com/)
 - [UltiMaker Cura](https://ultimaker.com/software/ultimaker-cura/)
+- [QMK](https://qmk.fm/)
 
 ## Resources
 
 - [FlatFootFox's Ergogen tutorial](https://flatfootfox.com/ergogen-introduction/)
+- [QMK documentation](https://docs.qmk.fm/)