3D printers offer possibilities while assembling

[Demon]

I'm been thinking of ways to make assembly easier and more accurate. Some of the devices I'm using are jiggly when using spec holes, and it's important for the devices to all be as exactly straight as possible (to fit in snug enclosure openings).

My solution; 3D printing an alignment tool.

Using manufacture recommended footprint:




3D printed tool:




Clips on board and holds switch perfectly upright:




Tool holds circuit and switch in vise:




It requires a few hours to get a routine established, but I think it's a good investment when you have 13 different devices. The switches will always be exactly upright.

It might not be a big deal when you're only doing a few devices, but I've got hundreds of these suckers to assemble.

[Ioannis]

Great idea.

What would you suggest for this faston soldering? I guess the 3D printed part will melt way too soon before I ever touch the second pin...!



Ioannis

[Demon]

You only need one drop of solder on the back to stabilize 1 pin.

Remove the support, solder the 2nd pin then go back and finish pin 1.

PLA has low -ish melting point. I just received some ABS, PETG and TPU for testing.

[Ioannis]

Every pcb has 5 of these and is not easy to do that. It is for a (small) production and takes time to deal with such nonsenses.

Besides, my wife is going to solder that boards, so I have to come up with an easy to use method. Usually pcbs are assembled on a device like this but the sponge that presses those pins, pushes them sideways.



Ioannis

[Demon]

... Usually pcbs are assembled on a device like this ...

I'm not sure I understand. Is that device used to dip the assembled PCB in a solder bath?

Or is it used to hold everything in place, then you flip and solder the bottom side?


I've been thinking about the heat applied to a lug like the one you're installing. I don't think the heat would transfer to an alignment tool that much, especially while soldering the first pin.

I'd solder them all only 1 pin, remove the tools, then solder the 2nd pins.

[Ioannis]

This orange device is for placing all through hole components, press with the sponge cover, flip on the other side and solder by hand.

This is not for a bath soldering, although you can place components then slide the pcb through a solder bath. Have not done that.

For SMDs either I order from JLCPCB the pcb with the SMD components (when low quantity is required) or for more mass production I order only the pcb then have locally a company with pick and place machines for assembly of the SMD part. The rest is done inhouse.

One idea for the faston parts would be to make holes smaller, though this come too tight to fit properly. It is risky.

Ioannis

[Demon]

Do you have a part number or link to that tab thingy?

EDIT: There's 4,975 models at Digikey. I'm looking for the exact specs of what you're using (height width, thickness).

https://www.digikey.ca/en/products/f...connectors/392

[Demon]

Great idea.

What would you suggest for this faston soldering? I guess the 3D printed part will melt way too soon before I ever touch the second pin...!

Attachment 9600

Ioannis

Ioannis, is it this one?

https://www.digikey.ca/en/products/d...cs/1287/124268

[Ioannis]

The buy was from a local retailer and I am afraid I may not be able to find the exact datasheet.

Though it looks very similar to the one you found on digi-key. Tomorrow I could measure the one I have and compare it to the digi-key.

Ioannis

[Ioannis]

Well, looks very similar to the one on post #8

Ioannis

[Demon]

Here's another cool thing you can make with 3D printers; a dust cover for potentiometers.

https://www.taydaelectronics.com/dus...ntiometer.html


I hadn't thought of this until I saw that item. I can make my own for my pots, use the same principle and cover the back of my SR-25 rotary switches completely.

[Demon]

...What would you suggest for this faston soldering?...

Do you do a lot of these? I can print 12 in 1.5 hours in PLA. That won't melt unless you poke it with the iron. PETG is even better, then ABS (but I haven't tried those yet).

I could order a few from Digikey to test the dimensions; to make sure you can slide it over a tab.

I didn't know how close you place these on the circuit. I can make it wider; it'll be even more stable.

[Ioannis]

Wow! What an idea the pot dust cover!

Thanks for the offer. But our local Customs Office will charge me about 150 euros for import taxes even if you send them to me as gift!

But the idea is very good and thank you. I may do this with wood. Hopefully...

Ioannis

[Demon]

That is freaking insane! :O

What if I send them to your neighbour? And then you can check his garbage when he throws them out?

[Ioannis]

Satanic...!

Well I am sure he will reject it in the first place.

Ioannis