Flashlight regulator board

[HarryN]

Hi, one of my crazy hobbies is playing with LED flashlights. Yes, you can buy them in a store, but what fun would that be? Of course, it will be a bit brighter than the off the shelf stuff.

I have had a board make in 1 oz copper before, and it is not too bad price wise, but the currents I am pushing really need at least 2 oz copper, and of course I do things a little excessively, so if I can actually obtain some 4 oz copper blanks, I may that route. Getting 2 or 4 oz copper made is a whole different price game at most places.

The board is approx 1 x 2 inches, and the finest traces are 1.27 mm pitch. (National LM22679 / TO 263 package.) I am not an EE, but know enough basics to draw it by hand, and I have a real EE making the eagle drawing for me. (in progress) I am hoping to have the files finished, and then run it through the g code conversion program in July 2009 - maybe sooner if I am lucky.

It is all single sided surface mount work, with just a few places for vias going to the bottom for grounds. I do not have a mill to do this work - is anyone interested in doing at least the traces for me? I could attempt to drill the through holes myself to make it easier.

Of course I would pay you as appropriate. I am not expecting you to give me a price at this point, as certainly there is not yet a picture, but if you might be interested in this kind of project, let me know.

Initially, there probably would be 1 or 2 boards. It could be more in the future if you are interested.

Thanks

HarryN

[HarryN]

Hi, since the response has been so overwhelming, perhaps I should lower my expectations. Would anyone consider to do this if it is just plain Jane 1 oz copper board ?

Thanks

HarryN

[JayC]

I'm interested. But I want to clarify some points:

1. Are you creating the eagle schematics and board layout and any original parts/packages? Or are you asking whomever to do that?
2. 1.27mm = .05". This is no problem
3. Drilling is no problem provided you use the same drill sizes that I own
4. You supply the PCB or you expecting whomever to supply it?

Jay

[HarryN]

Hi Jay, Thank you for replying.

I have some blank copper board on order which are 3 oz on each side, and would ideally like to use this material for the project. I should have it sometime in July. (Vacation timing challenges)

Like a lot of things, this is sort of a work in progress, and I don't yet have clear timing - but probably not before mid Aug.

Most of the schematic and board layout are being done by a guy in the UK that I met in a flashlight related forum. He is doing the layout / design work with my suggestions, and I am selecting parts based on his suggestions. So far, so good, but of course it is slower than if I really knew what I was doing and could run eagle myself correctly. He is using eagle lite 5.6

There have been 2 - 3 parts that had to be created and he handled this. They were off the shelf parts, but for some reason, it was easier for him to create them.

The board is sort of an oval shape. If you imagine 2 each 20mm dia. circles next to each other, then connect the tangents with lines that is the outside shape, so nominally 20 x 40mm.

There are 2 each through holes that are 5mm, 3mm, and 2mm that are mechanical holes.

The back of the board is entirely a ground plane, and so far, no traces are needed on the back of the board. All of the parts so far are top mounted SMT and I am trying hard to keep it that way. It is best if the final assembled board is VERY flat on the bottom.

The only electrical through holes are grounds running from the top to the bottom. I need to check what size holes my colleague is specifying so far. Some of them are just signal grounds, but a few carry 6 amps. I am open to suggestions on what to use for the connection, while toying with ideas like 16 or 18 gage solid copper wire or cut up parts leads, etc. I suppose in a pinch I could use silver filled paste.

I watched your YouTube video on making the board. For this project, I just need isolation milling. I am pretty sure that it does not require removal of the excess copper, but I will double check that aspect.

I have seen that someone posted on using a solder mask and that looks interesting, but I am not that far along yet. With 0402 size parts, that might be needed as well.

If you like, I can send you a copy of the file or a PDF. This is not the final version, but it will give you a sense of the project.

I did find a retired guy in San Jose that has a commercial board router and makes things on the side with it, but it requires another software translation, and then possible editing of that file. I am really hoping to be able to go directly from either the eagle file or gerber files directly (only editing the eagle file) so that if / when I make more of these at a board shop, there is less chance of error. If I can get these made at a reasonable price via machining, that is fine as well, since my volumes will be modest.

Thank you for your interest.

Harry

[admin]

Did you find anybody to make the pcb?

[HarryN]

Hi - sorry for not replying. Yes, Jay C is helping me with the board.

As it turns out, the LED mfg discontinued the LED package I was using, so I had to start over anyway.

There are always more projects - sometimes makes me wish I could do this myself, but you can't do everything.

Thanks and take care.

HarryN