It’s finally time to take the plunge and make Lightlog smaller and more robust. Moving away from the hand soldered, through-hole prototype boards, and to a custom multi-layer board using smaller surface mounted technology (SMT). Using specialist PCB layout tools such as Eagle CAD, and the Open Source KiCad, the prototype circuit needs to be re-created ready for a commercial board manufacturer to fabricate.
Commercial facilities requite a special set of custom files called Gerber files to produce boards with multiple circuit layers, vias (connections through the board), masking of areas from solder, front and back silk screen printing, drill holes, and the final board cutout shape. The image to the right shows the new board design, a full set of Gerber files can be found over on the Lightlog git repository.
The earlier electronics fitted within a box of 29mm x 29mm x 17mm, after these changes the size is down to 28mm x 26mm x 7.5mm. This might not seem like a huge saving, but by more than halving the thickness Lightlog is more discrete to wear and allows a wider variety of potential enclosure designs.
There are a number of part changes with the new board moving to the smaller SMT parts, but one more significant change is the new digital light sensor chip that I’ll try to cover in a future post.
Time to order a batch of these boards of testing!