One of my students Alex D. came to me with a circuit design for the "Eyes, Ears, Brain". This is an exercise that uses different hemispheres in the brain. (I'll will post a link later).
We were approached by an outside party to construct 30 of these boxes with circuits. while Alex did a few prototypes we had to come up with a method of mass production to cut down from a couple of hours of assembly down to less than 10 minutes. The first step was to make a template for the top of the box ass seen below.
Thanks to PMT for the aluminum and a #6 tap. This was the template we machine out, the two #6 screws hold the plastic top of the jiffy box. This sped our machine from a few minuite to a matter of seconds. see below
Once we had a solid template we could design a PCB that fit on top of the switches and solder in the LED's. The original prototype was point to point wiring that was very labor intesive. The new PCB could speed up assembly.
Here is a pic of a partially assembled project, we used 1/4 inch holes for all the LED and switches. If you notice the slices in the PCB, this was for the switch tabs. The tabare to big for the drill bit we have in stock (.04") so we elongated the holes with the cutout bit (.0625"). The slits in the middle of the board are from the battery clip strain relief.
Once the first one was done we did some revisions and I haded the PCB milling off to a very good student of mine Zach R. who has a great talent on running out milling machine. Below are a half dozen assembled.
Finished and working
If anyone would like the gerber files and schematic please email me, this is an open source hardware project. Input to the design is greatly appreciated.
(1) PVC BLK BOX
(3) Green LED
(3) 1/4 Watt Resistors
(3) LED holders
(1) 9V Batt Clip
(1) Solder 60/40
Alex D. - Principal contact for customer, Prototyping, Assembly Team
Zack R - Machinist for the PCB Mill, Assembly Team
N1IR - PCB designer, Template Design, Parts Procurement, Assembly Team