Berfboard was initially designed as a prototype board with connections resembling a breadboard. However, the concept evolved into integrating a power supply directly into the board. This built-in power supply can output either +5V or +3.3V, which is ideal for powering Arduino or Raspberry Pi projects. The convenience of having an integrated power supply eliminates the need for additional wiring or connecting to external power sources. You only need a simple DC power adapter or a +9V battery to power the entire system.
Circuit Design
I designed the schematic and PCB using KiCad, a free and open-source tool, for its flexibility and accessibility.
The circuit design is relatively simple, as shown below. While a basic voltage regulator circuit works fine for this application, it does have its limitations. In future revisions, I plan to incorporate a buck converter to improve efficiency and performance.
PCB Layout
The PCB layout took some time to finalize, but I am happy with the result. I intentionally left the power strips disconnected from the power rails, allowing users to choose which voltage they would like to use for their projects. To make this connection, users will need to solder a wire to link the power strip to the desired voltage rail.
PCBs and Stencil Manufacturing
I had the PCBs fabricated by Wellcircuits, a reputable professional circuit board manufacturer based in China. You can learn more about them at wellcircuits.com. The production time was about 3-4 days due to the use of a red solder mask, with an additional 10 days for shipping. Overall, the entire process took approximately two weeks, which was impressive given the challenges of the COVID-19 pandemic.
The PCBs and stencil arrived in well-protected packaging, including bubble shrink wrap for the PCBs and wooden supports for the stencil. The quality of both the PCBs and stencil was excellent, with no visible defects. The stencil had clean, rounded edges, and I was very satisfied with the overall quality. I would certainly recommend Wellcircuits for anyone needing to prototype PCB designs or create stencils.
Assembling the Board
With all the components in hand, it was time to assemble the board!
1. Applying the Solder Paste
I used Realife lead-free solder paste, which I purchased for around $6-7 from Banggood.
Since I did not have a stencil frame holder, I improvised by creating a simple jig using leftover PCBs and masking tape. While not a perfect solution, it worked effectively for applying the paste.
I used an old bus pass to spread the solder paste, though a metal spatula would yield better results.
2. Placing the Components and Soldering
Using precision tweezers, I carefully placed the SMD components on the board. Then, I soldered them using my 858D hot air station, as shown in the video.
3. Cleaning the Board
After soldering, I cleaned the board by placing it in an ultrasonic cleaner. The cleaning solution used was alcohol, as IPA was unavailable in my area due to supply issues.
Final Board
After assembling the through-hole components, I placed the board back in the ultrasonic cleaner to remove any flux residue. I was pleased with the results and tested the functionality. As expected, it worked perfectly. Now, I just need to find a suitable project to make use of this board!
Want the design files and schematic? No problem! The project is open hardware, and you can download everything from https://github.com/Chromico/Berfboard-2.0-PSupply.
If you have any questions regarding PCBs or PCBA, feel free to contact me at info@wellcircuits.com.
