Instructions for making a FX Light V2 PCB
********OLD NEEDS UPDATE FOR V2.1***********
Machine CNC Mill
Bit - 0.2mm straight bit Or <20 degree V-bit
Material 0.4mm Dual Side Copper Clad
The Front side requires no special alignment of the blank.
But it is very important when Milling a board this thin at 0.4mm dual side is to have a flat even surface. Differences of 0.1mm can ruin the cut.
I do not suggest placing the Copper Clad directly on the CNC surface as any miss alignment to the Z axis can cause damage to the CNC surface, the CNC motors, etc. Use a flat piece of plastic as a soft backer, and clamp all to the surface of CNC mill. Verify the surface is flat by Zeroing all axis and then moving the bit through the X and Y axis while keeping Z at 0.
Then cut away.
G-Code is below
Plus Picture References
Front Side Layout Of PCB (in mm)
Vertical Axis is Y
Horizontal Axis is X
Simulated Front Side Carve (Bottom Left Corner is Zero Reference)
Vertical Axis is Y
Horizontal Axis is X
After Cutting front side of board, flip who board over the Y axis.
Align the Zero now over the hole cut through the low left of the board (this hole is used only for this alignment.)
Pivot the board at point until the alignment hole directly above is on the same Y axis. (Align board straight)
Do this by visually aligning the CNC bit over top both alignment holes, moving only the Y axis of the CNC.
Once the holes are aligned, zero the CNC bit over the low left alignment hole.
Then Zero the Z axis for the surface height.
Better to start light, and do a second pass than run too deep.
Run Backside G-Code
Back Side Layout of PCB (in mm)
Vertical Axis is Y
Horizontal Axis is X
Simulated Front Side Carve (Bottom Left Corner is Zero Reference)
Vertical Axis is Y
Horizontal Axis is X
Once completed the board will be holding on by two small tabs on either side, and one end completed fixed. Cut the two tabs with a sharp knife, and then bend the whole PCB up and down until it breaks off board.
You now have a flat raw cut PCB. This cut needs to be sanded and cleaned. Then visually inspect very closely, as an tiny loose copper strand can cause malfunctions later on.
Clean between the traces using a sharp knife.
Clean the traces and copper strands with a 220 grit or higher.
Clean the holes by hand twisting a bit, first use a .5mm bit, then .6mm bit. then .7mm bit.
Once the PCB is cleaned, bend 90 degrees at the location cut on the back. Use a clamp or tools to hold the PCB firm and flat, and only bend at the required location. This bent portion will form the face to mount the LEDs on.
Solder a small amount on both edges on the backside of board to hold the bend at the required 90 degrees.
Now connect all grounds. Place 3 copper wires through the PCB holes. Solder the topside, making sure they are well aligned. Then flip over and solder the bottom side of the 3 copper wires. Solder one more wire at the front lower side (LED face) ground, to the back side, this will connect the LED grounds.
Use a flush cut to trim any excess wire.
Clean all with 70%-99% alcohol.
PCB Complete
*
G21
G90
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*
END of Front G-Code
START of Backside G-Code:
*
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*
END of Backside G-Code
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