KiCad: Generate gerber files for eepyBoard rev1

KiCad: Generate and finalize PCB file
Ergogen: Fix DRC issues in KiCad footprints
2024-08-04 16:21:27 +02:00 · 2024-08-04 16:17:51 +02:00 · 2024-08-03 23:31:51 +02:00 · 2024-08-03 22:50:36 +02:00 · 2024-08-03 22:20:51 +02:00
28 changed files with 310214 additions and 62 deletions
--- a/.gitignore
+++ b/.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
--- a/68
+++ b/68
@ -1,55 +1,21 @@
-# Blue Oak Model License
+MIT License

-Version 1.0.0
+Copyright (c) 2024 binaryDiv

-## Purpose
+Permission is hereby granted, free of charge, to any person obtaining a copy
+of this software and associated documentation files (the "Software"), to deal
+in the Software without restriction, including without limitation the rights
+to use, copy, modify, merge, publish, distribute, sublicense, and/or sell
+copies of the Software, and to permit persons to whom the Software is
+furnished to do so, subject to the following conditions:

-This license gives everyone as much permission to work with
-this software as possible, while protecting contributors
-from liability.
+The above copyright notice and this permission notice shall be included in all
+copies or substantial portions of the Software.

-## Acceptance
-
-In order to receive this license, you must agree to its
-rules.  The rules of this license are both obligations
-under that agreement and conditions to your license.
-You must not do anything with this software that triggers
-a rule that you cannot or will not follow.
-
-## Copyright
-
-Each contributor licenses you to do everything with this
-software that would otherwise infringe that contributor's
-copyright in it.
-
-## Notices
-
-You must ensure that everyone who gets a copy of
-any part of this software from you, with or without
-changes, also gets the text of this license or a link to
-<https://blueoakcouncil.org/license/1.0.0>.
-
-## Excuse
-
-If anyone notifies you in writing that you have not
-complied with [Notices](#notices), you can keep your
-license by taking all practical steps to comply within 30
-days after the notice.  If you do not do so, your license
-ends immediately.
-
-## Patent
-
-Each contributor licenses you to do everything with this
-software that would otherwise infringe any patent claims
-they can license or become able to license.
-
-## Reliability
-
-No contributor can revoke this license.
-
-## No Liability
-
-***As far as the law allows, this software comes as is,
-without any warranty or condition, and no contributor
-will be liable to anyone for any damages related to this
-software or this license, under any kind of legal claim.***
+THE SOFTWARE IS PROVIDED "AS IS", WITHOUT WARRANTY OF ANY KIND, EXPRESS OR
+IMPLIED, INCLUDING BUT NOT LIMITED TO THE WARRANTIES OF MERCHANTABILITY,
+FITNESS FOR A PARTICULAR PURPOSE AND NONINFRINGEMENT. IN NO EVENT SHALL THE
+AUTHORS OR COPYRIGHT HOLDERS BE LIABLE FOR ANY CLAIM, DAMAGES OR OTHER
+LIABILITY, WHETHER IN AN ACTION OF CONTRACT, TORT OR OTHERWISE, ARISING FROM,
+OUT OF OR IN CONNECTION WITH THE SOFTWARE OR THE USE OR OTHER DEALINGS IN THE
+SOFTWARE.
--- a/README.md
+++ b/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 `kicad/gerber/eepyboard_{REVISION}.zip`.
+4. Upload zip file to manufacturer and make sure everything is correct.
+5. Add all generated files to version control.
+
+### 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/)
--- a/ergogen/config.yaml
+++ b/ergogen/config.yaml
@ -392,7 +392,7 @@ pcbs:
        what: diode_smd
        where: is_key
        adjust:
-          shift: [ 7, -7 ]
+          shift: [ 7, -7.5 ]
          rotate: 90
          resist: true
        params:
--- a/ergogen/footprints/cap_0805.js
+++ b/ergogen/footprints/cap_0805.js
@ -8,6 +8,7 @@ module.exports = {
    body: p => `
        (module C_0805_2012Metric (layer ${p.side}.Cu) (tedit 5F68FEEE)
            ${p.at /* parametric position */}
+            (attr smd)

            ${'' /* footprint reference */}
            (fp_text reference "${p.ref}" (at 0 0) (layer ${p.side}.SilkS) ${p.ref_hide} (effects (font (size 1.27 1.27) (thickness 0.15))))
--- a/ergogen/footprints/choc_pretty.js
+++ b/ergogen/footprints/choc_pretty.js
@ -28,6 +28,7 @@ module.exports = {
        const standard = `
            (module PG1350 (layer F.Cu) (tedit 5DD50112)
                ${p.at /* parametric position */}
+                (attr smd)

                ${'' /* footprint reference */}
                (fp_text reference "${p.ref}" (at 0 0) (layer F.SilkS) ${p.ref_hide} (effects (font (size 1.27 1.27) (thickness 0.15))))
@ -56,11 +57,13 @@ module.exports = {
        `;

        function switch_marks(reversed) {
-            let def_side = reversed ? 'F' : 'B';
+            // Draw switch marks on the front side (the side with the switches, not with the sockets)
+            let def_side = reversed ? 'B' : 'F';

            return `
                ${'' /* switch marks */}
-                (fp_line (start -7 -7) (end  7 -7) (layer ${def_side}.SilkS) (width 0.15))
+                (fp_line (start -7 -7) (end -1.5 -7) (layer ${def_side}.SilkS) (width 0.15))
+                (fp_line (start 1.5 -7) (end  7 -7) (layer ${def_side}.SilkS) (width 0.15))
                (fp_line (start  7 -7) (end  7  7) (layer ${def_side}.SilkS) (width 0.15))
                (fp_line (start  7  7) (end -7  7) (layer ${def_side}.SilkS) (width 0.15))
                (fp_line (start -7  7) (end -7 -7) (layer ${def_side}.SilkS) (width 0.15))
--- a/ergogen/footprints/diode_smd.js
+++ b/ergogen/footprints/diode_smd.js
@ -8,6 +8,7 @@ module.exports = {
    body: p => `
        (module SmdDiode (layer ${p.side}.Cu) (tedit 65D012FE)
            ${p.at /* parametric position */}
+            (attr smd)

            ${'' /* footprint reference */}
            (fp_text reference "${p.ref}" (at 0 0) (layer ${p.side}.SilkS) ${p.ref_hide} (effects (font (size 1.27 1.27) (thickness 0.15))))
--- a/ergogen/footprints/rp2040_purple.js
+++ b/ergogen/footprints/rp2040_purple.js
@ -107,7 +107,7 @@ module.exports = {
            for (let i = 0; i < PINS_PER_SIDE; i++) {
                pin_pad_body += `
                    (pad ${i + offset} thru_hole circle (at ${sign}8.89 ${pin_pos_y(i)} 0)
-                        (size 1.7526 1.7526) (drill 1.0922) (layers *.Cu *.SilkS *.Mask) ${p[pin_names[i]]}
+                        (size 1.7526 1.7526) (drill 1.0922) (layers *.Cu *.Mask) ${p[pin_names[i]]}
                    )`;
            }
            return pin_pad_body;
--- a/ergogen/footprints/sk6812_mini_e.js
+++ b/ergogen/footprints/sk6812_mini_e.js
@ -13,6 +13,7 @@ module.exports = {
    body: p => `
        (module SK6812-MINI-E (layer F.Cu) (tedit 53BEE615)
            ${p.at /* parametric position */}
+            (attr smd)

            ${'' /* footprint reference */}
            (fp_text reference "${p.ref}" (at 0 0) (layer ${p.side}.SilkS) ${p.ref_hide}
@ -30,19 +31,19 @@ module.exports = {
            (fp_line (start -1.7 1.5) (end -1.7 -1.5) (layer Edge.Cuts) (width 0.12))
            (fp_line (start -1.7 -1.5) (end 1.7 -1.5) (layer Edge.Cuts) (width 0.12))

-            (pad "1" smd rect (at -2.55 -0.75 ${p.r}) (size 1.7 0.82)
+            (pad "1" smd rect (at -2.6 -0.75 ${p.r}) (size 1.6 0.82)
                (layers "${p.side}.Cu" "${p.side}.Paste" "${p.side}.Mask")
                ${p.VCC}
            )
-            (pad "2" smd rect (at -2.55 0.75 ${p.r}) (size 1.7 0.82)
+            (pad "2" smd rect (at -2.6 0.75 ${p.r}) (size 1.6 0.82)
                (layers "${p.side}.Cu" "${p.side}.Paste" "${p.side}.Mask")
                ${p.dout}
            )
-            (pad "4" smd rect (at 2.55 -0.75 ${p.r}) (size 1.7 0.82)
+            (pad "4" smd rect (at 2.6 -0.75 ${p.r}) (size 1.6 0.82)
                (layers "${p.side}.Cu" "${p.side}.Paste" "${p.side}.Mask")
                ${p.din}
            )
-            (pad "3" smd roundrect (at 2.55 0.75 ${p.r}) (size 1.7 0.82)
+            (pad "3" smd roundrect (at 2.6 0.75 ${p.r}) (size 1.6 0.82)
                (layers "${p.side}.Cu" "${p.side}.Paste" "${p.side}.Mask")
                (roundrect_rratio 0.25)
                ${p.GND}
--- a/kicad/eepyboard.kicad_pcb
+++ b/kicad/eepyboard.kicad_pcb
--- a/kicad/eepyboard.kicad_pro
+++ b/kicad/eepyboard.kicad_pro
--- a/kicad/gerber/eepyboard_rev1.zip
+++ b/kicad/gerber/eepyboard_rev1.zip
--- a/kicad/gerber/rev1/eepyboard-B_Cu.gbr
+++ b/kicad/gerber/rev1/eepyboard-B_Cu.gbr
--- a/kicad/gerber/rev1/eepyboard-B_Mask.gbr
+++ b/kicad/gerber/rev1/eepyboard-B_Mask.gbr
--- a/kicad/gerber/rev1/eepyboard-B_Paste.gbr
+++ b/kicad/gerber/rev1/eepyboard-B_Paste.gbr
--- a/kicad/gerber/rev1/eepyboard-B_Silkscreen.gbr
+++ b/kicad/gerber/rev1/eepyboard-B_Silkscreen.gbr
--- a/kicad/gerber/rev1/eepyboard-Edge_Cuts.gbr
+++ b/kicad/gerber/rev1/eepyboard-Edge_Cuts.gbr
@ -0,0 +1,731 @@
+%TF.GenerationSoftware,KiCad,Pcbnew,8.0.4*%
+%TF.CreationDate,2024-08-04T16:18:39+02:00*%
+%TF.ProjectId,eepyboard,65657079-626f-4617-9264-2e6b69636164,1.0*%
+%TF.SameCoordinates,Original*%
+%TF.FileFunction,Profile,NP*%
+%FSLAX46Y46*%
+G04 Gerber Fmt 4.6, Leading zero omitted, Abs format (unit mm)*
+G04 Created by KiCad (PCBNEW 8.0.4) date 2024-08-04 16:18:39*
+%MOMM*%
+%LPD*%
+G01*
+G04 APERTURE LIST*
+%TA.AperFunction,Profile*%
+%ADD10C,0.150000*%
+%TD*%
+%TA.AperFunction,Profile*%
+%ADD11C,0.120000*%
+%TD*%
+G04 APERTURE END LIST*
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--- a/kicad/gerber/rev1/eepyboard-F_Cu.gbr
+++ b/kicad/gerber/rev1/eepyboard-F_Cu.gbr
@ -0,0 +1,803 @@
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--- a/kicad/gerber/rev1/eepyboard-F_Mask.gbr
+++ b/kicad/gerber/rev1/eepyboard-F_Mask.gbr
@ -0,0 +1,934 @@
+%TF.GenerationSoftware,KiCad,Pcbnew,8.0.4*%
+%TF.CreationDate,2024-08-04T16:18:39+02:00*%
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+G04 Created by KiCad (PCBNEW 8.0.4) date 2024-08-04 16:18:39*
+%MOMM*%
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+G01*
+G04 APERTURE LIST*
+G04 Aperture macros list*
+%AMRoundRect*
+0 Rectangle with rounded corners*
+0 $1 Rounding radius*
+0 $2 $3 $4 $5 $6 $7 $8 $9 X,Y pos of 4 corners*
+0 Add a 4 corners polygon primitive as box body*
+4,1,4,$2,$3,$4,$5,$6,$7,$8,$9,$2,$3,0*
+0 Add four circle primitives for the rounded corners*
+1,1,$1+$1,$2,$3*
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+1,1,$1+$1,$6,$7*
+1,1,$1+$1,$8,$9*
+0 Add four rect primitives between the rounded corners*
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+20,1,$1+$1,$6,$7,$8,$9,0*
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+G04 Aperture macros list end*
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+%ADD13C,2.300000*%
+%ADD14RoundRect,0.050000X-0.775000X-0.650000X0.775000X-0.650000X0.775000X0.650000X-0.775000X0.650000X0*%
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+G04 APERTURE END LIST*
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--- a/kicad/gerber/rev1/eepyboard-F_Paste.gbr
+++ b/kicad/gerber/rev1/eepyboard-F_Paste.gbr
@ -0,0 +1,23 @@
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--- a/kicad/gerber/rev1/eepyboard-F_Silkscreen.gbr
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+T3
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+X284.953Y-65.802
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+M30
--- a/kicad/gerber/rev1/eepyboard-job.gbrjob
+++ b/kicad/gerber/rev1/eepyboard-job.gbrjob
@ -0,0 +1,169 @@
+{
+  "Header": {
+    "GenerationSoftware": {
+      "Vendor": "KiCad",
+      "Application": "Pcbnew",
+      "Version": "8.0.4"
+    },
+    "CreationDate": "2024-08-04T16:18:39+02:00"
+  },
+  "GeneralSpecs": {
+    "ProjectId": {
+      "Name": "eepyboard",
+      "GUID": "65657079-626f-4617-9264-2e6b69636164",
+      "Revision": "1.0"
+    },
+    "Size": {
+      "X": 253.15,
+      "Y": 132.3846
+    },
+    "LayerNumber": 4,
+    "BoardThickness": 1.6,
+    "Finish": "None"
+  },
+  "DesignRules": [
+    {
+      "Layers": "Outer",
+      "PadToPad": 0.2,
+      "PadToTrack": 0.2,
+      "TrackToTrack": 0.2,
+      "MinLineWidth": 0.25,
+      "TrackToRegion": 0.508,
+      "RegionToRegion": 0.508
+    },
+    {
+      "Layers": "Inner",
+      "PadToPad": 0.2,
+      "PadToTrack": 0.2,
+      "TrackToTrack": 0.2,
+      "TrackToRegion": 0.508,
+      "RegionToRegion": 0.508
+    }
+  ],
+  "FilesAttributes": [
+    {
+      "Path": "eepyboard-F_Cu.gbr",
+      "FileFunction": "Copper,L1,Top",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "eepyboard-In1_Cu.gbr",
+      "FileFunction": "Copper,L2,Inr",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "eepyboard-In2_Cu.gbr",
+      "FileFunction": "Copper,L3,Inr",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "eepyboard-B_Cu.gbr",
+      "FileFunction": "Copper,L4,Bot",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "eepyboard-F_Paste.gbr",
+      "FileFunction": "SolderPaste,Top",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "eepyboard-B_Paste.gbr",
+      "FileFunction": "SolderPaste,Bot",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "eepyboard-F_Silkscreen.gbr",
+      "FileFunction": "Legend,Top",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "eepyboard-B_Silkscreen.gbr",
+      "FileFunction": "Legend,Bot",
+      "FilePolarity": "Positive"
+    },
+    {
+      "Path": "eepyboard-F_Mask.gbr",
+      "FileFunction": "SolderMask,Top",
+      "FilePolarity": "Negative"
+    },
+    {
+      "Path": "eepyboard-B_Mask.gbr",
+      "FileFunction": "SolderMask,Bot",
+      "FilePolarity": "Negative"
+    },
+    {
+      "Path": "eepyboard-Edge_Cuts.gbr",
+      "FileFunction": "Profile",
+      "FilePolarity": "Positive"
+    }
+  ],
+  "MaterialStackup": [
+    {
+      "Type": "Legend",
+      "Name": "Top Silk Screen"
+    },
+    {
+      "Type": "SolderPaste",
+      "Name": "Top Solder Paste"
+    },
+    {
+      "Type": "SolderMask",
+      "Thickness": 0.01,
+      "Name": "Top Solder Mask"
+    },
+    {
+      "Type": "Copper",
+      "Thickness": 0.035,
+      "Name": "F.Cu"
+    },
+    {
+      "Type": "Dielectric",
+      "Thickness": 0.1,
+      "Material": "FR4",
+      "Name": "F.Cu/In1.Cu",
+      "Notes": "Type: dielectric layer 1 (from F.Cu to In1.Cu)"
+    },
+    {
+      "Type": "Copper",
+      "Thickness": 0.035,
+      "Name": "In1.Cu"
+    },
+    {
+      "Type": "Dielectric",
+      "Thickness": 1.24,
+      "Material": "FR4",
+      "Name": "In1.Cu/In2.Cu",
+      "Notes": "Type: dielectric layer 2 (from In1.Cu to In2.Cu)"
+    },
+    {
+      "Type": "Copper",
+      "Thickness": 0.035,
+      "Name": "In2.Cu"
+    },
+    {
+      "Type": "Dielectric",
+      "Thickness": 0.1,
+      "Material": "FR4",
+      "Name": "In2.Cu/B.Cu",
+      "Notes": "Type: dielectric layer 3 (from In2.Cu to B.Cu)"
+    },
+    {
+      "Type": "Copper",
+      "Thickness": 0.035,
+      "Name": "B.Cu"
+    },
+    {
+      "Type": "SolderMask",
+      "Thickness": 0.01,
+      "Name": "Bottom Solder Mask"
+    },
+    {
+      "Type": "SolderPaste",
+      "Name": "Bottom Solder Paste"
+    },
+    {
+      "Type": "Legend",
+      "Name": "Bottom Silk Screen"
+    }
+  ]
+}
Author	SHA1	Message	Date
Lexi / Zoe	4e7f80ceac	KiCad: Generate gerber files for eepyBoard rev1	2024-08-04 16:21:27 +02:00
Lexi / Zoe	b137f90ee0	KiCad: Generate and finalize PCB file	2024-08-04 16:17:51 +02:00
Lexi / Zoe	f438b19352	Ergogen: Fix DRC issues in KiCad footprints	2024-08-03 23:31:51 +02:00
Lexi / Zoe	671f85b13e	Ergogen: PCB fine tuning (diode position, choc switch marks)	2024-08-03 22:50:36 +02:00
Lexi / Zoe	076c1cc500	Replace license with MIT	2024-08-03 22:20:51 +02:00