Re: [AH] PCB manufacture (was DX7 Vs...sx200?)

From doug
Sent Mon, Oct 1st 2018, 14:20

On 2018-09-30 23:47, Brian Willoughby wrote:
> On Sep 30, 2018, at 7:43 PM, xxxx@xxxxxxxx.xxx wrote:
>> On 2018-09-30 13:56, Brian Willoughby wrote:
>>> On Sep 30, 2018, at 10:07 AM, xxxx@xxxxxxxx.xxx wrote:
>>>> On 2018-09-29 14:12, matrix wrote:
>>>>> If you look at Casio's VZ-1 there are buttons with LEDs that allow 
>>>>> you
>>>>> to enable and disable each operator.  I would love an FM synth that
>>>>> had similar buttons above a control section that instead of 
>>>>> enabling
>>>>> or disabling the operators, they enabled or disabled the controls 
>>>>> for
>>>>> each operator.  That way you could select what operators were 
>>>>> affected
>>>>> by the FM depth, harmonic control, etc..  Even with the Jellinghaus
>>>>> and Detronics DT7 I think you have to adjust each parameter 
>>>>> separately
>>>>> vs. having groupings you can assign.
>>>> The DX7 programmer I've designed allows multiple operator editing by 
>>>> using a common set of controls for the operators (and switches to 
>>>> select the operators to edit), which reduces cost significantly and 
>>>> makes the programmer smaller (3U rack), but sacrifices dedicated 
>>>> sliders for each operator.  I put the development on hold to focus 
>>>> on other programmers, once the DT7 was announced, but perhaps it's 
>>>> time to thaw the project.
>>> Hey, Doug. Would it be possible for a die-hard fan of the DX7 to buy 
>>> 6
>>> of your programmers and use them in parallel? It might be worth the
>>> effort of a few firmware tweaks to enable that possibility. Then, 
>>> most
>>> customers could buy just one programmer, but some really serious FM
>>> programmers could link 6 of them (or 4, if your programmer works with
>>> the 4-op Yamaha FM).
>>> Brian
>> 
>> It would be possible to daisy chain 6 without any firmware tweaks 
>> (they have merging MIDI inputs).  However, if someone were interested, 
>> it would be simpler (and a lot less expensive) for me to build a 
>> dedicated 9U version, since it's just a firmware update and a few more 
>> panels.  It may even fit it in 6U, if I use 20mm sliders (instead of 
>> 60mm).
> 
> Thanks for the response, Doug. I’m fascinated by designing PCB layouts
> so that the same board can be reused for multiple products, from the
> smallest (most affordable) to the largest (only for crazy folks with a
> huge budget). I suppose you’d need a new PCB to change from 60mm to
> 20mm sliders, but maybe the PCB fab is not the most expensive part of
> your manufacturing costs.
> 
> I’m currently designing a device that can generate CV, and it can be
> expanded by 8 CV channels at a time, up to 40 CV outputs in one
> device. This is probably a lot cheaper than a custom 40-CV product
> because the same 8-CV boards are just plugged in together. This way, a
> bulk order of boards can be made to hopefully get a discount on fab,
> and then everyone benefits from the lower cost.
> 
> Brian

FWIW, my latest batch of boards (8"x3U) can mix and match 20mm, 60mm, 
and toggle switches, so the layout is more flexible than my earlier 
PCBs.  I have 10 programmers currently in the pipe (using this board), 
which I hope to have out by Christmas, although that's probably wishful 
thinking.  The core (processor) board is a daughter board, so I can swap 
out different core boards to accommodate 1-6 interface boards, making 
expanding as easy as swapping a daughter board and adding a single 
cable.  The core boards are also based on the Arduino Uno, so the 
firmware is very accessible and editable by the end user (I plan on 
posting the firmware on my site some day soon).  I'm also working on an 
Arbitrary Waveform Generator with this board, which is similar to an 
analog sequencer for SysEx.

I hate to admit it, but I've had to move overseas for PCB manufacturing. 
  I used to use Advanced Circuits and OSH Park here, but Advanced 
Circuits prices increased 30% in 6 months (they say it's due to 
tariffs), so it forced me to look elsewhere, since PCB manufacture was 
one of my biggest expenses (other than bulk slider purchases from 
Bourns).  Also, PCB mistakes were very expensive, since large boards are 
very expensive at OSH Park and Advanced Circuits has a $600 minimum 
order.  I'm now using Seeed Studios, which cost much less, don't have a 
minimum order requirement, and have a similar turn-around time as 
Advanced Circuits (including shipping overseas), which is great for 
prototyping and production.  PCBs under 100mm x 100mm are ridiculously 
cheap, which is why I've been able to experiment with daughter boards 
and come up with various 4" boards to use when the 8"x3U boards are 
overkill.

---
Doug Huseby
http://synthark.com
http://synthark.org