Newsgroups: comp.robotics
Path: brunix!sgiblab!swrinde!emory!news-feed-2.peachnet.edu!concert!corpgate!nrtpa038!brtph862!sherlock
From: sherlock@brtph862 (Steve Holmes NT)
Subject: Re: Help in Developing PC Board
Message-ID: <CnJ487.LDx@nrtpa22.bnr.ca>
Sender: cadnews@nrtpa22.bnr.ca (netnews posting host)
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Organization: BNR, Research Triangle Park, NC
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References: <2nctst$45a@geraldo.cc.utexas.edu>
Date: Thu, 31 Mar 1994 12:33:41 GMT
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Tan (cftan@foghorn.cc.utexas.edu.cc.utexas.edu) wrote:
: Hi,
: 	I am planning to develope my own PC Board by 1st printing the final
: design on transparancy. Then use photo sensitive chemical....

Arghh,

I don't do it unless you really have to. It's a bit of a mess
and until you have done quite a few the results are usually not
that satisfying.

Alternate Solution:

AP Circuits and their Proto 1 service, It will cost you about 
$100 bucks but you'll be kinder to your environment.  Here is
there new user info from their BBS.  They also have a 
freeware/shareware layout tool on the BBS.

Steve Holmes
sherlock@bnr.ca

Sorry for the length and width of the attachment, but I thought it would
save people from downloading from the BBS just for information.


Attachment:


AP Circuits is a unique circuit board manufacturing facility, specializing in
fast turnaround prototypes and short-run production.  We have served the
commercial sector for eight years making plated-through hole and single-sided
circuit boards.

The laminate used in the manufacture of our circuit boards is FR4 epoxy glass. 
We add one oz. of copper to half oz. laminate, and the finish is reflowed
solder.  Our resolution is .008" lands and .008" spaces.  This means that there
should not be any spaces less than .008" between the lands and there should not
be lands any less than .008" wide. 

Our 24 hour bulletin board service enables you to upload your files to us at any
time. Our BBS will test file transfers for integrity and immediately inform you
of pass/fail status.  After we have checked your data we will post a message to
you on the BBS E-Mail section letting you know that your job has begun processing 
or to describe the problem encountered and suggest solutions. 

SERVICES

We offer two distinctly different services.  The basic difference between the
two is the total area of your order and your requirements, such as solder masks,
etc.

PROTO 1 (UP TO 400 SQUARE INCHES) 

The purpose of Proto 1 is to provide plated-through hole circuits for testing or
short run projects.  We require the number of circuits ordered be two, or
multiples of two.  The only laminate used in the Proto 1 service is 1/16" FR4. 
Component or solder masks are not available in Proto 1, and due to the small
quantities involved, we cut the boards out in simple rectangles, four straight
line cuts per board.  The maximum size of circuit board we can manufacture is 
13.4" long by 11.4" wide. The minimum size for area calculations is 
1.5" by 1.5 inches.  If you have multiple boards you can panelize them to 
save money but be sure to leave space to cut them apart.  You can use a hack 
saw or a band saw for this purpose.  Single-sided pcb's are manufactured with 
plated through holes in the Proto 1 service.   

If your order is received by midnight Sunday we will ship the circuit boards by
Friday of that week, providing there is no problem with the data or information.
                                                      
PROTO 2 (300 TO 3000 SQUARE INCHES) 

Proto 2 provides the full range of services the designer may require, such as
laminates of different thicknesses, solder/component masks, cutting to unusual
shapes,  etc.  Maximum size of boards is the same as the Proto 1 service.  Proto
2 orders not requiring solder/component masks are shipped within 10 working
days.  Orders with masks may take up to 20 working days.

We are primarily a prototyping service do not offer gold plating.

ORDERING PROTO 1

For us to be effective in delivering your order on time, we must get all the
information we need, from the initial transmission.  To streamline the ordering
process for you, we are writing a program that will save you time and help to
eliminate errors by asking all the necessary questions and ensuring that all the
necessary files are named.  At the end of the order, the program will zip all
the files and the resulting zip file is ready for transmission.  This program
will be available at the end of November and will be sent to all of our
customers.  Until this program is available please use the "ASCORDER.DOC" order
form which is included in the New User file if you have downloaded from the
modem.
JOB STATUS

When we first began the Proto 1 service, we stated that the status of the
customers work could be checked on the BBS at any time.  This statement
requires some clarification.  The Proto 1 jobs are set up Monday morning or 
before if time permits and by Monday afternoon, any jobs that we cannot 
proceed with, have to be held for the next Proto 1 processing.  Time constraints 
dictate that we must get to the plotting stage Monday evening if we are to 
ship your Proto 1 order by weeks end.  Due to these constraints, the only 
status posted is a "hold" status with the explanation of a problem, or a 
"processing" status to let you know your job has been set up and is presently
being processed.  This status is available within two working days of the upload
date.  For customers who send their order in before Thursday we post a status
on Fridays.  For customers who ship their order over the weekend the status is 
available Tuesdays.  You can see why we need all the information to be 
complete and correct.  If you upload your order late Friday or over the 
weekend, we will not find any problems until it is too late for you to 
correct the data and your order will not be shipped by the end of the week.

README FILES 

There is an area in the new order program to insert special instructions or you
can transmit a readme file with your order.  There is a place in the order
program to enter the "readme" file name.  This will make sure that the
instructions will be read before the job is started.  Until the order program is
available please use the "readme" file to transmit special instructions.

CAD DATA 

In order to manufacture your boards, we require Gerber and NC Drill files,
preferably in 2.3 format.  That is two digits leading the decimal location and
three digits trailing.  There should be no decimal points in your data.  
Your CAD system will have several file generation options.  We require a
pure text file type (ASCII format).

Your  Gerber images should appear exactly as you drafted them, component side on
top with a through board view, component side text is right reading and solder
side text reversed.  Do not flip or rotate any of the images or drill data.

When you convert your drafting file to Gerber, the program uses an aperture
table to define the codes used in the Gerber files.  In order for us to plot
your Gerber files we must have your aperture table.  Be sure to include that
file with the data you send us.  


Orcad USERS - NC generation, use the LZ option
Tango USERS - Gerber generation, use the 5.3 option
Protel USERS - Title Block OFF + Match tolerances to ZERO

It is highly recommended that you examine your Gerber and NC Drill files with a
Gerber viewing utility prior to sending them to us for processing.  It is a
large jump of faith to assume the cad program will generate the Gerbers and the
aperture file exactly as you intend.  We recommend a third party software
package be used for accurate results.  If you do not have access to a Gerber
view program, we have one available, without charge, on the BBS, called
GERBVIEW.   

The GCPREVUE program (GERBVIEW) will display the layers, drill data, aperture
and drill definitions provided you load them and you can send us the ".WRK" file
from GCPrevu instead of the Gerbers files if you choose.  Be sure all the
necessary files are loaded if you take this route.IMPORTANT NOTES

There are six files needed for basic board manufacturing:
        order form
        2 Gerber files of top and bottom foil layers
        Aperture file (defining Gerber codes)
        NC drill file (locations of the holes)
        Tool file (defining the size of the drill bit for tool numbers)
Solder/component masks require a Gerber file for each mask.
                                                                       
We suggest you identify your board with text on the top foil layer.  
This is one of the few ways we can check for layer swaps.  
Please place crop lines at all four corners of the board on each of the foil
(conductor) layers, and ensure that there is nothing outside of the crop lines
such as title blocks or other text or it will be included in the calculation of
your image area. 

Negative image plotting to produce ground planes is not available. 
Ground plane areas must be created by your Cad system using copper pour type
applications.  

If you require solder masking in Proto 2 service please ensure you solder mask
pads are .020" larger than the pad on the foil layer.

DRILL SCHEDULE (PROTO 1)

We have listed the most common drills for you to choose.   You can use any or
all of the sizes listed below at no additional charge.   If you require a size
not listed, there will be a $12.50 additional charge for each extra drill size. 
Sizes available are .028 inch to .152 inch, or wire sizes 70 to 24.   Be sure to
allow for plating in the holes which decreases the diameter of the hole by about
.003". 

Wire Size  Unfinished Finished   Uses

70         .028       .025       Via
65         .035       .032       IC
58         .042       .039       Resistors, Diodes, TO220, etc.
55         .052       .049       Switches, Wires, Headers
53         .060       .057       Switches, Large Headers
44         .086       .083       TO220 Mounting, etc.
1/8"       .125       .122       Mounting Holes
24         .152       .149       Mounting Holes

An average of 24 holes per square inch over the board area is the maximum number
of holes to qualify for the prototype prices.  There is an extra charge for
boards with more than 24 holes per square inch.  

DRILL SCHEDULE (PROTO 2)

You can specify six drill sizes and use our tooling bit sizes at no additional
charge. We use a 1/8" and a .052" drill for tooling purposes.  We add $7.50 for
each additional drill size specified.   Sizes available are .028" to .152".
Holes larger than .152" must be routed after the board is processed and will not
be plated through.
PRICING (PROTO 1) including all plotting and tooling

To calculate the price of a circuit board, multiply the maximum measurements in
the X and the Y direction to obtain the area in square inches, then multiply by
the number of boards you want ie. 2, 4, 6...(even number quantities only) to get
the total area of your order.   Take the total area and apply it to the
following formula.   The minimum order is two circuit boards.  The minimum size
is 1.5 inches by 1.5 inches.

              TOTAL SQUARE INCHES x .85 + 60 = COST IN $

EXAMPLE: 
   5" x 4" board = 20" sq.x 2 boards (minimum) = 40 square inches.  

                 40 square inches x .85 + 60 = $94.00 

Increasing you order may dramatically reduce the cost per board. 

EXAMPLE: 
6 pieces of the 5" x 4" board = 120 square inches x .85 + 60 = $162.00 

This works out to about $27.06 each compared to $47.00 each when ordering only
two boards.

PRICING (PROTO 2)  plotting and tooling included

The pricing formula for Proto 2 service is approximate because many more options
are involved. To calculate an approximate price of an order over 300 sqare
inches use the following formula the same way as you used the Proto 1 formula.
You then add for the masks.  Shipping costs are determined by weight.

              TOTAL SQUARE INCHES x .27 + 300 = COST IN $
              SOLDER/COMPONENT MASKS          = $85.EA.
           
              *NOTE ALL PRICING IS IN CANADIAN DOLLARS* 
   
UNITED STATES CLIENTS 

U.S. clients will benefit from their stronger dollar when converting to Canadian
funds.   The current exchange rate for U.S. currency is posted in our "News"
bulletin which is displayed when you log in to the BBS.   All pcb's qualify
under the Canada/U.S. Free Trade Agreement (N.A.F.T.A.).   

There are no additional charges to you for Customs Duty.

PAYMENTS

In order for us to begin work on your order immediately, we require either a
money order, company cheque, or your VISA or Master Card number with expiry date
and the name of the cardholder.  Credit cards are billed in Canadian dollars and
are converted by the credit card company.  Business accounts are available to
companies doing $300 to $400 monthly.
  
SHIPPING

The fastest, least expensive method of shipping your order is by our overnight
courier. (TNT in Canada or Airborne in the U.S.) There are no extra charges for
customs clearance as with UPS or Fedex. There is a minimum charge of $25.00 that
covers most Proto 1 orders. In some remote areas the service is a two day
service.  For orders under $100.00 we can use the mail but there has been 3 week
delays in delivery, and we have to wait six weeks to begin tracking procedures
with the post office.
FREEWARE     

We have freeware that you can download from our BBS at no cost (recommend
minimum 2400 Baud).  These are fairly large files.   It may be less expensive to
send you a diskette rather than to download over the telephone.   If you would
like us to send you a diskette, please include $10.00 for shipping and
handling.(IBM compatible only).

EASYTRAX (BBS FILE: EASYFREE.EXE/ZIP)

This is the full blown version that used to list at $450.00 U.S.   Protel has
now released this software to the public sector.   The manual has been converted
to ASCII text and is now included in the EASYFREE.EXE file.  This is an entry
level PCB layout program, with Gerber file and  NC drill file generation. This
program is not limited in any way and all work files are upward compatible with
the rest of Protel's product line.

PKZIP (BBS FILE: PKZ204G.EXE)

This program is a compression utility that should be used to reduce the size of
files to be sent by modem or to pack a diskette.   

GCPREVUE (BBS FILE: GERBVIEW.EXE/ZIP)

This program is used to view Gerber files.   We recommend that all files be
examined with this program before you send them to us.  

Thank you for your interest in our service.   We would be happy to answer any
other questions you may have.

                WE DO NOT DISCLOSE INFORMATION ABOUT OUR CLIENTS,  
                  OR THEIR WORK.  YOUR NAME, DATA, AND ALL OTHER
                 INFORMATION IS HELD IN THE STRICTEST CONFIDENCE  

                                AP Circuits Ltd.  
                               (403) 250-3406 Voice
                                (403) 291-9342 BBS 
                          Wayne Bamber / Dan McMuldroch 
