Added manufacturing details

docs/content/docs/manufacturing/_index.md

@@ -1,7 +1,7 @@
 ---
 title: Manufacturing
 prev: /docs/design/open_ems
-next: /docs/manufacturing/jlcpcb
+next: /docs/manufacturing/ordering
 weight: 3
 params:
     icon: cog

docs/content/docs/manufacturing/electrical_testing.md

@@ -7,26 +7,31 @@ params:
   icon: badge-check
 ---
 
-## Checking for shorts
-- Oculink port after reflow can be shorted due to excess or smeared solder paste resulting in bridges between fine pitch pins
-    - Can redo reflow as many times until short is gone
-- For flex pcb shorts can occur between fine pitch SMD pads of FFC connector
-    - Visual inspection through transparent FFC can reveal where shorts are
+## Single board validation
+- Oculink port has a small pitch of 0.2mm which can easily create solder bridges.
+- Validate this by connecting the Oculink port to the unpowered PCIe eGPU board.
+- Refer to [M.2 pinout]({{< abs_url link="/docs/specifications/components/" >}}) and [PCIe pinout]({{< abs_url link="/docs/specifications/pcie_specification/" >}}) for the electrical connections to test for.
+- Depending on the design the PCIe lanes may be connected in opposite polarity and/or in opposite orders.
+- Check for short circuits and bad connections.
+- Use a magnifying glass to position multimeter probes onto the exposed electrical contacts.
 
-## Checking flex pcb during assembly
-- For flex pcb bad connections can be checked partially through assembly
-- Begin by soldering FFC to M.2 card
-    - Check for shorts and bad connections between M.2 edge connector and end of FFC cable
-- Begin reflowing oculink port to separate PCB
-    - Check for shorts on exposed connector pads
-- Bad connection or short will likely be located at FFC to oculink board connection
+## Flexible PCB multi board design
+Validation of flexible PCB design will be done in three passes.
 
-## Checking assembled board 
-- Connect oculink adapter to eGPU board
-- The PCIe connector on the eGPU board can be used to check for continuity and shorts
-    - Refer to following schematic for pin out of PCIe connector
-- Use m.2 edge connector as other side of connection
-    - Refer to pinout for m.2 connector
+{{< responsive_image key="kicad_flex_connector_render" >}}
 
+### 1. Oculink port board
+- After Oculink port has been soldered to PCB perform similar checks as with the single board design.
+- Instead of using the M.2 connection use the exposed flexible PCB SMD pads to test for shorts or bad electrical connections.
 
+### 2. Flexible PCB to Oculink port
+- After soldering flexible PCB to Oculink port board perform the same check but with the exposed flexible PCB pads on the M.2 side of the flexible PCB.
+- Perform visual checks of the flexible PCB at the soldered connection. Since the polyimide is translucent it is possible to detect solder bridges.
+- If there are any shorts or bad connections they are likely isolated to the flexible PCB connection since we have already verified the Oculink port itself.
+
+### 3. Flexible PCB to M.2 port
+- After soldering flexible PCB to M.2 card perform same check as with the single board design.
+- Perform visual checks of the flexible PCB at the soldered connection. Since the polyimide is translucent it is possible to detect solder bridges.
+- If there are any shorts or bad connections they are likely isolated to the flexible PCB connection on the M.2 card side.
+- Due to steps 1 and 2 the Oculink port and flexible PCB connection on the Oculink board side are verified.
 

docs/content/docs/manufacturing/ordering.md

@@ -0,0 +1,80 @@
+---
+title: Ordering
+prev: /docs/manufacturing
+next: /docs/manufacturing/reflow_soldering
+weight: 1
+params:
+  icon: cog
+---
+
+> [!NOTE]
+> All prices are listed in $USD.
+
+## JLCPCB
+### Single board design
+- 0.8mm thickness
+- 4 layers
+- 120mm by 80mm
+
+| Part | Cost |
+| --- | --- |
+| Base | $2.00  |
+| 4 layer 0.8mm stackup required HASL finish | $4.80 |
+| 4 layer stackup above 50mmx50mm | $5.00 |
+| Engineering cost of boards above 100mmx100m | $24.00 |
+| **Total** | **$35.80** |
+
+### Flexible PCB design
+#### M.2 card
+- 0.8mm thickness
+- 4 layers
+- 22mm x 42mm
+
+| Part | Cost |
+| --- | --- |
+| Base | $2.00 |
+| 4 layer 0.8mm stackup required HASL finish | $4.80 |
+| **Total** | **$6.80** |
+
+#### Oculink port board 
+- 1.6mm thickness
+- 4 layers
+- 87mm x 21mm
+
+| Part | Cost |
+| --- | --- |
+| Base | $2.00 |
+| 4 layer stackup above 50mmx50mm | $5.00 |
+| **Total** | **$7.00** |
+
+#### Flexible PCB
+- 0.11mm thickness
+- 2 layers
+- 83mm by 77mm
+
+| Part | Cost |
+| --- | --- |
+| Base | $2.00 |
+| **Total** | **$2.00** |
+
+#### Total cost of all boards
+| Board | Cost |
+| --- | --- |
+| M.2 card | $6.80 |
+| Oculink port board | $7.00 |
+| Flexible PCB | $2.00 |
+| **Total** | **$15.80** |
+
+## Components
+The components for both the single board design and multi-board flexible PCB design are identical.
+
+| Part | Unit Cost | Quantity | Total |
+| --- | --- | --- | --- |
+| Amphenol Oculink port <br>(G14A42121B12HR) | $3.50 | 1 | $3.50 |
+| SOD52 Schottky diode | $0.25 | 1 | $0.25 |
+| X7R 040 10nF MLCC | $0.05 | 5 | $0.25 |
+| **Total** | | | **$4.00** |
+
+- Components were ordered from [Mouser Australia](https://au.mouser.com/).
+- There are minimum order quantities for the Oculink port connector which has a MOQ of 5.
+- Price of extra components are not considered since we are just interested in cost of a completed M.2 to Oculink adapter board.

docs/content/docs/manufacturing/reflow_soldering.md

@@ -1,33 +1,78 @@
 ---
 title: Reflow soldering
-prev: /docs/manufacturing/jlcpcb
+prev: /docs/manufacturing/ordering
 next: /docs/manufacturing/electrical_testing
 weight: 2
 params:
   icon: fire
 ---
 
 ## Equipment
-- Reflow plate
-- Soldering iron
-- Magnifying glass
-- Isopropyl alcohol
+- Reflow soldering plate.
+- Soldering iron with a conical tip.
+- Magnifying glass.
+- Isopropyl alcohol.
+- Metal tweezers.
 
-## Reflow oculink port
-- Apply stencil for oculink connector, make sure there are no bridges
-- Place oculink port
-- Apply reflow
+{{< responsive_image key="mechanic_ix5_reflow" style="width: 50%" >}}
+{{< responsive_image key="ts100_soldering_iron" style="width: 50%" >}}
 
-## SMD components
-- Can apply stencil
-- Easier to solder by hand
+## Reflow profile
+1. Set a target temperature on the Mechanic IX5 reflow plate.
+2. Activate the reflow process which will increase the temperate by 1°C each second until target temperature is reached.
+3. Once the reflow temperature is reached let it remain at this temperature until reflow has finished.
+4. Allow the PCB to cool which decrease temperature by 1°C each second until it is cool enough to handle.
 
-## FFC connector for flex pcb
-- Need to apply pressure to connector while reflow occurs for complete contact
-- There is not alot of tolerate for FFC connector when soldered since there is mechanical slack, it has to be as flat to the SMD pads as possible
-- When reflowing connector place weights to apply even pressure across FFC connector
+{{< responsive_image key="reflow_profile" >}}
 
+The Mechanic IX5 can be used to follow an arbitrary reflow profile (including the shown trapezoidal or delta types). The delta type reflow profile is sufficient for the Oculink port.
 
+## Instructions
+### Reflow soldering components
+1. Apply stencil for Oculink connector and capacitors to spread solder paste.
+2. Visually check to make sure there are no bridges or missing solder paste on SMD pads.
+3. Place oculink port carefully onto SMD pads as to align them correctly.
+4. Follow reflow profile with a target temperature of 220°C and keep it there for 60 seconds before ramping it down.
+5. Visually confirm that there are no solder bridges on visible connections.
+6. Validate that there are no shorts or bad connections following [electrical testing]({{< abs_url link="/docs/manufacturing/electrical_testing" >}}).
+    - Due to simple design of circuit the complications should only occur with the Oculink port itself.
+    - Here excessive or insufficient solder paste can result in short circuits or a missing electrical connection.
+    - Repeat steps 1 to 5 until the Oculink port is soldered correctly.
 
 
+For the flexible PCB design continue to the following instructions below.
 
+### Soldering flex connector
+This process is only required for the two part board which is connected over the flexible PCB.
+
+1. Perform reflow soldering of components for each of the two boards as described above.
+2. Tin the SMD connection pads on both the flexible PCB and M2 card and Oculink port board.
+    - Make sure that there is a minimal amount of solder to prevent shorts when reflow soldering connector.
+    - Check to see if amount of solder has same height across all pads. If there isn't remove it until it is level.
+3. Focus on the Oculink port board first and preheat it to 140°C.
+4. Preheat the soldering iron with the conical tip to 280°C.
+5. Using metal tweezers carefully position the flexible connector to align with the SMD pads.
+    - Add flux to the flexible connector and board will help keep the connector in place once aligned.
+    - Do this under a magnifying glass with mechanical helper hands.
+6. Using the soldering iron solder the ground SMD pads after alignment.
+    - Be careful to not misalign the connector.
+    - Increase the preheating temperature of the board to 150°C or above if soldering isn't occuring.
+    - Avoid preheating the board to too high of a temperature otherwise solder may become molten and components and Oculink port can be knocked off.
+    - Avoid keeping the board preheated for too long otherwise PCB will discolour.
+    - Make sure that you have soldered enough of the ground pads to keep the connector in place.
+7. Let the Oculink port board cool down and check that flexible PCB is **mechanically** secure enough to move assembly around.
+    - At this step there is no sound electrical connection between the board and flexible PCB.
+    - We only need it to be mechanically secure so we can perform the full reflow step under mechanical pressure.
+8. Place a weight on top of the flexible PCB connection to equally apply force on the SMD pads.
+    - The weight should cover the entire flexible PCB connection pads.
+    - The weight should not melt at the reflow temperature of 220°C.
+    - The weight should be secure and stationary during reflow process.
+9. Perform reflow soldering of the flexible PCB connection while the connections are under constant force.
+    - Since there are no spring contacts, the z-height tolerance of the connection is very low.
+    - To guarantee a good electrical connection the reflow process has to occur while the pads are under compressive pressure.
+    - Be careful not to disturb the existing connections such as the Oculink port and capacitors.
+10. Perform electrical tests as described in [electrical testing]({{< abs_url link="/docs/manufacturing/electrical_testing" >}}).
+    - This is done to make sure shorts don't occur due at the flexible PCB connection with the Oculink port board.
+    - If shorts do occur at this step repeat steps 1 to 10 with less solder on the pads.
+    - If these is a missing electrical connection make sure that sufficient pressure has been applied during reflow.
+11. Repeat setps 1 to 10 for the M.2 card.

docs/data/images.yaml

@@ -175,3 +175,13 @@ openems_taper_reflectance_overall:
 openems_taper_s_params_overall:
   description: "S-parameter results of parameterised search of taper ground plane across all parameters"
   path: "/images/diagrams/openems_taper_s_params_overall.png"
+mechanic_ix5_reflow:
+  description: "Mechanic IX5 reflow heating plate"
+  path: "/images/diagrams/mechanic_ix5_reflow.png"
+ts100_soldering_iron:
+  description: "TS-100 soldering iron"
+  path: "/images/diagrams/ts100_soldering_iron.png"
+reflow_profile:
+  description: "Reflow profile"
+  path: "/images/diagrams/reflow_profile.png"
+  source: "https://www.7pcb.com/blog/lead-free-reflow-profile"