Integrating DfM into electro mechanical design environments

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Integrating DfM into electro- mechanical design
environments

• Paul Wright,Berkeley Wireless Research Center,
  and
• Berkeley Manufacturing Institute, 2001

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Beyond Prototypes!! Design for Manufacturing
Concerns for Pico Radio Testbed

• Must add draft angle and fillets to part. This
  will add complexity to the model and slightly
  increase the size of the part. Part will be
  slightly conical instead of perfectly cylindrical
  to allow part removal from the injection mold.
• Currently two sliders are required to form the
  serial port access hole and the power switch
  hole. Both holes need to be designed out.
• We will need to use larger screw bosses to
  account for draft angle - PCB cut-outs
  (hopefully) have been enlarged to account for
  this.
• Add a feature to screw the PCB directly to the
  casing??
• Case lid should be stiffer.
• Casing design is small enough to be shot on our
  in-house injection press.
• EDM will be required to make this mold. We must
  located an external vendor for this.

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Our MCAD tools

• AutoCAD, Solidworks
• SDRCs IDEAS, OpenCascade

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Our ECAD tools

• Cadences ORCAD
• Will be used for Bluetooth radio boards,
  schematics and PCB designs
• (Old BWRC CAD tools were Zuken Redac for Layout,
  Routing, Manufacturing and Viewlogic for the
  schematics)
• Checking that these new tools can export and
  import new standards from the ISO

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BWRC
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STEP

• The Standard for the Exchange of Product model
  (STEP) Provides a common method of defining
  product data
• Application Protocols (APs) define the content,
  scope and information requirements of a
  designated application area

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STEP protocols AP203 and AP210

• All mechanical CAD systems export and import STEP
  files in the AP203 protocol
• Electronic assembly interconnect and packaging
  design is now described in AP210

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STEP AP210

• April 1999
• ISO (International Organization for
  Standardization) accepted STEP Application
  Protocol as International Standard
• Electronic Assemblies, Interconnection and
  Packaging
• Printed Wiring Assemblies (PWA)

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AP210 Content

• Permits the exchange and sharing of
  computer-interpretable product requirements data
  and product definition data with customers,
  suppliers, business partners or others in a
  mutually understood methodology

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Conclusion Where we are now at BWRC

• First PicoNode completed and tested in Summer
  2000 (Fused Deposition Model)
• Injection molding rules have now been implemented
  for larger batch of nodes
• Mold making and injections being organized now
  for completion in late Spring