From debug messages to the fundamental ‘hello world’, serial communication does it all over three little wires. Now imagine being able to cut the cord to your next microcontroller project and use your phone as a VT100 terminal. This was the premise of [Ondřej Hruška]’s Wireless Terminal Project where he took an ESP8266 and added an in-browser terminal emulator which can be accessed…
Castellations are small plated edges, typically used for making circuit boards into small PCB modules. These are often seen on wireless modules, such as the ESP8266-12E.
While we don’t offer full support for castellations, they can be fabricated if you don’t mind a few minutes of rework and verification of the PCBs.
It’s helpful to include a fallback hole near the edge. The ESP8266-12E boards, are a great example here. The extra via allows easy connecting of wires for rework, and makes it easy to salvage a module if the fabricated PCB doesn’t turn out perfectly.
Indicating in the design file
Castellations are simple to call out in most design tools. Simply include a via on the PCB, so the board outline goes through it.
However, due to our panelization process, the castellated vias must be indicated with round pads for copper and stop mask. The pads must also not extend more than 40 mil from the board edge. Square pads or pads that extend far beyond the edge will be trimmed, and the via will not be plated.
It’s also helpful to use a 10 mil wide line for the board outline. With our milling tolerance of 5 mil, this provides a good visual indicator of where the physical board edge might be. The fabricated edge can be anywhere within that line. This is very helpful for fine-pitch castellations with smaller holes.
Rectangular castellations can be made by using vias with round pads as noted above, and adding overlapping rectangular SMD pads. Since these pads are inside the board outline, they will not be trimmed, and will provide additional area for soldering (see below for example).
Cleaning up the final boards
We make a best-effort to minimize support tabs on castellated edges, but it sometimes happens. In these cases, you’ll need to file the tab off of your edge.
Additionally, the via plating may not be fully removed during the milling process. In some cases it’s smashed next to the edge, where it can cause unwanted connectivity between vias. In others, it’s smashed inside the via, where it will prevent good solder flow. A fine point file or hobby knife will help remove excess plating.
We like the novel orientation of pogo pins that Wing Tang Wong used in this board design:
Upcycles D1 Mini Wemos board to create a USB connected ESP8266 Pogo pin jig
This is a board designed to take a WeMos D1 Mini board(with the ESP module removed) and use it as a USB interface with built-in reset/flash functionality for bare ESP8266 modules similar to the ESP-12 units.
The design files are available on GitHub:
This shield for the D1 Mini ESP8266-based development board adds a joystick and three buttons, so that you can implement menus or games on your device easily.
deshipu has shared the board on OSH Park:
thingSoC is an Open Source socket system for IoT development and has just launched a new Crowdy Supply campaign:
Build any IoT or Networked device you can imagine!
The thingSoC Grovey! platform gives you the freedom to choose from hundreds of existing sensors, actuators, and radios to quickly create new electronic systems, in plug together configurations that were not possible before. Easily mix together different CPUs, Radios, and Peripherals, like Servos, Motors, Relays, Sound and Lights, and then program them in your choice of Integrated Development Environments (IDE).
The thingSoC Grovey Series files are available on GitHub:
- TSOC_Teensy3x: Teensy3.x Adapter for the Grove System
- TSOC_GROVEY_ONE: Model “Uno” Arduino Clone for the Grove System
- TSOC_GROVEY_FOUR: Model “Four” PSoC4 mini for the Grove System
- TSOC_GROVEY_WIFI: ESP8266 Wi-Fi Adapter for the Grove System
- TSOC_GROVEY_I2CHUB: I2C Hub/Switch for the Grove System
- TSOC_GROVEY_GPIO: SX1509 GPIO for the Grove System
- TSOC_GROVEY_UART: USB to UART for the Grove System
A very fun Internet of things project to control the custom RGB led over the internet from a web-browser or enjoy a nice sound reactive experience. Perfect for a smart home setup as you can easily connect this to any IoT platform or smart home software
- 0:45 – zPulse intro
- 1:00 – Designing the board in EagleCad
- 7:45 – Sending the board to a manufactured to get fabricated
- 8:40 – Applying soldering paste to the Board
- 11:25 – Baking the board and components
- 15:27 – Powering on the board for the first time!
Daniel Grießhaber created this convenient tool to test your WiFi Security against attackers:
Demonstrate how easy it is to crack a WiFi Password or jam your WiFi so you can’t access the internet. Designed for education and self-tests.
ESPTool has the following hardware:
- SSD1306 based OLED Display, connected via I2C
- microSD Card Socket connected over the SPI interface
- 3 general purpose buttons
- ESP8266-12E Module
- TPS63031 Buck-/Boost-Converter with an input range from 1.8V – 5.5V
- MCP73831 Single-Cell LiPo Charger Chip
- CP2012 USB to UART converter Chip
The design files and source code are available on GitHub: