PCB on Roland MDX-15/20
Prepare Eagle
Read this for the fablab CAM method for milling the board
http://fablab.marcboon.com/pcb/
Install these files (download at the end of this page):
Rev 7 or Rev 6 of eagle needs these files:
Makeitlabs_Mill_Drill In the Eagle ULP directory (in x:\Program Files (x86)\EAGLE-7.3\ulp)
use Notepad or other text editor to add this to the end of the eagle.def file in eagle (in x:\Program Files (x86)\EAGLE-7.3\bin)
Copy the Cam job, Roland1sided.cam to (in x:\Program Files (x86)\EAGLE-7.3\cam).
Download Dropout or any chose of serial output utility.
Process A PCB
run the Fab-lab-ulp-e6.ulp
use 0.63 mm for the tool diameter
the milling layer is where the isolation traces will be placed..
the drilling layers is where the hole drills will be placed
CAM open job Roland2sided.cam
offset 0.1
Output the Files
load the cam job (Roland1sided.cam)
X, Y offset needs to at least the tool size. Note one the mirrored bottom side, if uses, needs the PCB X width added to the offset.
Check the Files
The output files are text files that look like this:
PA;PA;VS2;!VZ4;!MC1;!PZ-5,20;
PU2000,1000;
PD2000,2950;
PD3137,2950;
PD3137,1000;
PD2000,1000;
...
Check the files. NO NEGATIVE X or Y values EVER!
The drill file can not have any side motion. This will snap the drill instantly.
PU = pen up, PD = pen down, PZ-5,20 = cut .005" inches down, safe retract is 0.02" up.
"touch down", Z zero is set on the front panel of the roland with the up / down buttons.
X, Y units are .0009", e.g. PD1016,1016 puts the mill bit at X 1", Y 1", Z 0
VS = XY speed in MM/S, VZ = Z speed in MM/S
XY velocity depends on the tool size, and the PCB material
Max tool speed is VS2 for a 0.015" tool one 1 oz copper pcb, Recommended speed VS2.
Max tool speed is VS6 for a 0.025" tool on 1 oz copper pcb, Recommended speed VS3.
Exceeding these speeds will result in tool damage or worse.
Setting up Files to Run
There will be 3 files to run: tmill (traces), route(cutting out the PCB), and tdrill (through holes)
The zero is set by the up / down pushbuttons on the front panel.
The tool up and down positions (Z axis) in the files are set relative to the zero.
The default value will need changed per each pass of the file run; use notepad or other text editor to modify the pen down value.
The value !PZ-5,20 is mill 0.005" into the PCB and use 0.020" above the PCB for travel moves.
It is best not to use more than 0.005" per pass for a 0.025" cutter.
Loading a PCB on the Roland
Use frost king double sided tape on PCB blank material. The tape needs to be place under the entire outline to be cut.
Spacing between the tape rows should be no more than the tape width.
Setting up Roland to Run
Add the test_org.txt file to drop out and send it. This will place the head at a x, y axis location (0.1"x0.1") that can be used for the z axis zero.
Load the 0.025" cutter and Zero the tool height at 0.004" above the copper surface. Note this will mean that !PZ-5,20 should cut only 0.001" into the PCB. If the PCB is not flat to 0.001" a second pass may need to run to complete all traces.
Running the Files
Add the file.tmill file to drop out. Send the file. Observe the mill running.
edit the !PZ-x,20 to a value new x value if needed. Save the file and run the file.
Remove the file from dropout's list.
Add the file.route file to drop out. Send the file. Observe the mill running.
edit the !PZ-x,20 to a value new x value -5 for each step, until pcb is cut though ( 0.065" or .035")
Remove the file from dropout's list.
load the drill (faster) or use the mill for larger holes (mounting holes)
Add the job.tdrill file to drop out. Send the file. Observe the mill running.
edit the !PZ-x,20 to a value new x value -5 for each step, until pcb is cut though ( 0.065" or .035")
Or if the drill is used add -25 to each pass (-5, -30, -55, -80).
Remove the file from dropout's list.
Stopping a Run
Press the view button on the front of the roland.
Run as admin the DeletePrintJobs.cmd file.
press both the up and down arrow keys and wait for the LED to stop blinking.
Press the view botton and resume use.
Reference
Where to get tools http://www.pmtnow.com/end-mill/ET