5/16/2023 0 Comments Defcon badges![]() ![]() I’ve been to the DEFCON Las Vegas hacking convention for three years now, and I wanted to share my experiences. It’s important to get this right with any PCB design or the results could be disastrous*.While I know this may not be the preferred spelling, I want to repurpose ALL of my old DEFCON convention posts, so here we go! ![]() That means filled areas correspond to a lack of solder mask in that area. Those of you familiar with the Gerber format will know that all Gerber layers are positive except for the solder mask layers, which are negative. We suggested going for purple solder mask instead due to the points mentioned before so the files had to be modified. Runs the risk of peeling and blistering and so extra boards may need to be madeįor these boards, Seeess initially came knocking with the Gerber files of two silkscreen layers for the purple ‘skin’ and the black outline, and a white solder mask layer. Layers and even the integrity of the solder mask. The additional baking steps can further affect the colors of the previous Literally pokes holes in the wallet and extends the lead time. Each color must go through a separate round of application,ĭeveloping, curing and cleaning which, as additional manufacturing steps, Custom solder mask is one thing, having multiple layers isĪnother. Yellow, for example, is a very weak color and more translucent than others. Also, the mixing is an art itself, you have to consider the properties of the different colors. Two batches made using the same factory can have vastly different results. Making it doubly expensiveįor a custom color, it’s a case of just mixing two different colors together, but the colors can change as they go through the developing and curing processes making it difficult to predict the final outcome. Solder mask color, we have an extra solder mask layer. Main challenges with boards like the Tor badge. The closest alternative would be to have darkish purple solder mask and silvery HASL surface finish for the flesh? It’s not the same. For this board though, I’m sure Seeess would agree that it was definitely worth it. Of course, this comes at considerable extra expense – even for relatively simple designs, so expect to pay up. In such production lines, every order is dealt with individually and production processes are adjusted according to the specific requirements of the design, whether it’s a special combination of parameters, laminate stack-up, intricate copper pattern or something else. That is where the traditional “Premium” production facilities come in. Giving the boards character and individuality and the top wowers are willing to Solder mask oils are no longer a simple gimmick, they’re the main aesthetic, Red, yellow, black and white nowadays, and it’s increasingly more common toįind other crazy colors like orange, baby blue and even clear solder mask. Quickturn factories can offer the relatively standard rainbow of green, blue, Multitude of colors sometimes at the same cost as the standard green. Sure you know, solder mask resist now comes readily available in a wide ![]() If they suddenly switch to a special solder mask color, then they need to clean the silkscreens or set-up a new station, especially for this order. If one needs extra solder mask coatings, then the whole panel goes along for the ride.Įssentially, they have no capacity to produce them and are simply not interested in the extra effort. So if one customer’s design needs a special color, then all the boards on the panel will have that color. That means everything is handled on a panel-by-panel basis. In the typical PCB production process, everything is processed together until they are milled apart – one of the final production steps. But after enquiring at various fabs, the scale of his proposal quickly sunk in.īasically, you are not going to be able to achieve any kind of custom solder mask design with the cheaper quickturn factories – the kind that panelizes orders from different customers together to save on materials and handling steps. ![]() With help from a designer, Seeess had the Gerber files ready for his three tone boards. This time, fully aware of Defcon’s high standards, Seeess decided to fork out the cost and effort for an awesome badge design. Prior to coming to Seeed, Seeess had tried other fab houses for the previous badge runs. We also have an assembly video to top things off. Particularly, regarding the vibrant design for the PCB nerds out there. Having had a personal input in the preparation and manufacture of these boards, I thought it would be neat to share some of the challenges Seeess and Seeed Fusion faced in the production of these boards. SAO, great for randomly adding blinky scallions to other Defcon badges. Combined with the simplicity of the circuit, it makes a neat little Striking aspect about this badge has to be the bi-color custom solder maskĭesign. ![]()
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