This tutorial shows how to get started and reflow your first test board.
Stretch goal :
ReflowR reached its stretch goal of $12000 on 10 December, Now all reflowR’s will ship with an additional free Test Kit that contains a small functional test PCB, Small stainless steel stencil, 100 Components, 10 Gram solder paste, 10 ml Flux, Anti-Static tweezers and a small stainless steel squeegee.
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Hands on experience with electronics is vital to demystify the bits that spill out when learners drop their iPhones. By playing with real electronic components, learners will realize that mastering modern technology is within their grasp and the way to become tomorrow's technology leaders is to excel in STEM (Science,Technology, Engineering and Maths) subjects.
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As parents and teachers it is our responsibility to give the next generation those experiences to inspire them to excel in STEM subjects, so get a reflowR and a the STEM inspiration kit.
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* Stress reducing - Less worry that human error will burn your board and ruin your effort and parts, less worry that thermal shock will make your board fail as soon as it leaves your hands and ruin your reputation.
* Inspirational teaching/ learning aid - Children( and adults) are inspired more by what they can do, than by what they are shown.
* Superior even temperature - Unlike heavy cast pans, electric aluminium skillets or toasted ovens that are designed to cook food, The reflowR is designed specifically to heat PCB's, it uses a special large flat heater element and thick aluminum plate right between the heater and the top plate to spread the heat evenly across the entire PCB without uneven cold spots like with this $400+ toaster oven and controller example.
* Multifunction - Reflow , Rework, MSD bake or Rework pre-bake. A total of 8 profiles are available from the start button, and with the WiFi upgrade 128 profiles are available.
* Compact and convenient size - Your reflowR can be kept with other desktop tools without occupying excessive space.
* Access - You have full access to the parts being reflowed while the solder is kept melted to enable small adjustments to fix misalignment.
* Proper PID temperature control - JEDEC reflow profiles compliant. Small heat capacity and thermal mass, with active cooling and microprocessor control delivers fast, accurate temperature rise and fall.
* Process monitor and logging - Each of your reflow jobs gets logged for later comparison and inspection.
* Energy efficient design - Due to the low thermal mass, ReflowR heats your PCB, not your office.
* Improved reliability - Reliable solder joints and Less risk of thermal shock to your components.
* Improved quality - reflowR won't discolor your boards and your solder joints will be smooth and shiny.
* Consistency - each board is reflowed almost exactly the same, eliminating human error and variation due to hots spots in skillets and toaster ovens.
* Superior rework function - Reworking large parts like Quad Flat Packs (QFP) can be problematic when having to apply heat with a hot air pencil or trying to hold a board on a skillet while trying to prod the part with tweezers or a soldering iron, all the while rushing and panicking that you are over heating the part or damaging the board. With a reflowR the board will be held in place, and brought up to just the right temperature so that you can place and exactly re-align the the part without stress on the part or your nerves.
* Available and affordable - to the maker, professional or as an educational tool.
* Web app and open web service - In addition to the phone app, reflowR will have a web app so it can be controlled from any browser. It will also have a JSON based web service so you can write your own app and control the reflowR directly if you like.
* Auxiliary Thermocouple input - provides an optional external second thermocouple input to monitor temperature either at the top of the PCB or on large components such as connectors. Consider adding a Auxiliary Thermal Probe Upgrade which includes a K type thermocouple.
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Depending on the model the following functions are available:
* Reflow function - Both reflowR models are capable of re-flowing a board and follows the selected JEDEC profile.
* MSD Bake function - Some electronic components are MSD (Moisture Sensitive Devices) and must be dried for several hours at an exact temperature prior to being placed. ReflowR can bake your parts at the correct temperature according to the JEDEC requirements. (IPC/JEDEC J-STD-033B.1 section 4 / Table 4.1)
* Controlled Rework function - The reflowR has clamps to hold your PCB in place so that rework can proceed with a hot air station or soldering iron. In addition the PCB can be pre-heated and kept at a set temperature (60°C to 160°C ) to ease the removal of large components while reducing excessive localized heat stress. (IPC/JEDEC J-STD-033B.1 section 6.1) The temperature can also be set to just high enough to easily align QFP and other large parts.
* Rework pre-bake function - Similar to the MSD bake some boards should be pre-baked before rework proceeds to prevent damage to other components when reworking a board. (IPC/JEDEC J-STD-033B.1 section 6.2).
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The reflowR uses a universal PSU, and has an Input voltage range of 100-240V.
The reflowR models are differentiated as follows:
* Smart reflowR -This is the best reflowR for makers and learners. Make it even better by adding a WiFi Upgrade.
* Large reflowR -This reflowR is the best for professionals that often reflow large or panelized boards. Make it even better by adding a WiFi Upgrade.
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The inspiration kits gives you everything you need to practice and build some fun mini projects with modern surface mount components. The mini projects work independently, interconnect or work as Raspberry PI / Arduino accessory boards. Suitable for learners age 8 and up.
The idea is that you will be able to connect inputs and outputs in various combinations or connect them to Arduino or raspberry PI boards.
Each project is progressively more challenging to build and understand.
There are 4 small PCB’s , on a panel just like what would be used in a fabrication facility.
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Project 1 is a simple to build and understand 10 Led Counter based on a 74HC4017 logic IC in a SO16 package with 10 LEDS and 3 passive components.
Project 2 is a de-bouncing button input with On/Off toggle latch LED and digital output, simple to build, but the digital logic is bit more challenging to understand. It is based on a 74HC4011 logic IC in a SO14 package with 2 LEDS and 12 passive components.
Project 3 is a signal conditioner and detector, simple to build, but the analog circuit is bit more challenging to understand, it is based on a LM358 Op-amp in a SO8 package with a LED and 18 passive components.
Project 4 is a Multi function dual D-type flip-flop circuit , this project is more challenging to build and understand. It is based on a 74HC74 in a DHVQFN14 package, measuring only 2.5x3mm compared to the 4 x 8.5 mm of the SO14 package. It has 2 LEDs and 34 passive components.
The inspiration kits do not include a reflowR, you must add a reflowR to your order.
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The reflowR does expose a small hot surface, but it is no more dangerous than a skillet or toaster oven. Learners under the age of 13 should be supervised when using the reflowR . Not suitable for children under the age of 4 due to small parts.
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To keep the costs of the reflowR to a minimum, the included shipping is via surface mail / small packet post, but this can take 60 days or more to arrive. If you would like your reflowR sooner please add an Airmail or EMS (Expedited mail service) upgrade perk. Actual delivery does vary by country and state. Your local authority may impose taxes or duties on delivery.
Over the years I have established working relationships with several electronics and laser cutting contract manufacturers capable of fulfilling any quantity ordered.
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What if I lose some of the small components? The learner kits come with extra components so you should be ok.
Can the learner kits be reused?
Yes, the components can be removed and the boards reused a number of times. Each kit comes with extra components so SMT pasting, placing and soldering can be practiced over and over.
Can I reflow larger PCBs or PCB panels?
Yes, although not ideal, it is possible to relow sections of a PCB at a time.
What is the maximum board size for the Smart ReflowR?
The board size is not limited by the model, the board can extend over the edge so you can reflow a board in sections, although this may not always be ideal or desirable. The smart reflowR top is 150 x 80 and the large reflowR is 200x150 - makers seldom do SMT boards bigger than this.
What is a JEDEC profile ?
JEDEC is an industry body that sets standards.
You can read more about the solder reflow process at this Wikipedia page.
A reflow profile looks like this (courtesy Wikipedia) :![]()
The Smart reflowR and Large reflowR are microprocessor controlled and will follow the profile quite closely, further they are programmable and you can select and tune the profile to your requirement.
Could the refllowR be controlled over wifi also with PC (Linux/Windows/Mac) or there will be only a smartphone App?
ReflowR will also have a web app so it can be controlled from any browser. It will also have a JSON based web service to write your own app if you like.
How do I use the reflowR?
The reflowR has a very simple user interface, one button and a buzzer, after power on, count the button presses to select the reflow profile number, then after 4 seconds the reflowR will do it's thing. Before it exists the reflow stage the buzzer will beep every 4 seconds, then each time you press the button the reflowR will remain in the reflow zone for 45 seconds longer, so you can have time to rework the board.
If you have the WiFi upgrade, the reflowR will appear as a access point, you can then connect to the app and update the profiles (4 preset + 4 user defined) and view the actual profile achieved in the last cycle,
Redditors Question 1 : I tried using a heavy cast pan but found it very inconsistent across the whole surface compared to the reliability of using IR, I only tried it a couple of times before I gave up. Do you honestly find surface heating from underneath reliable?
Answer:
Aluminum is about 5 times more thermally conductive than cast iron. So the cast iron pan is more likely to have spots.
An electric aluminium skillet being designed to cook food has its own issues, the heat is focused along a narrow area right above the narrow element and with the aluminum being quite thin it takes long to spread the heat.
The reflowR is designed to heat PCB's, it uses a flat heater element and thicker aluminum plate right between the special large flat heater and the top plate to spread the heat evenly.
Redditors Question 2 : I just lay a 7 inch by 7 inch square of 1/4 inch thick aluminum plate on my electric heater. Spreads the heat quite evenly.
Your competition might include (this) device for $110 including shipping.
Answer:
A simple ¼ inch ali plate on a hot plate is how I have reflowed many boards in the distant past, but a hot plate/heater easily overshoots the temperature. One way to avoid an overshoot is to watch the reflow carefully then remove the ali plate from the hot plate while the solder is still molten. This is a very manual process and you have to pay attention, one slip up and your board is ruined. Plus you are not sure about the heating profile, possible latent damage to parts can cause the board to fail soon after it leaves your hands and that can ruin your reputation. ReflowR makes this process more reliable.
The linked hot plate is just temperature controlled hot plate, it would do the job of a $10 hot plate a lot better but it is not going to do the job of a reflowR, you have no control over the profile so thermal shock is still a huge risk.
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The reflowR is a spin off from my Many-maker project. I needed to reflow a hand built PCB for the many-maker and after scouring the internet for a modern solution, I realized makers and even professionals are still reflowing PCBs with skillets and toaster ovens! Not only are they bulky but they also produce questionable quality. So I decided to make my own reflowing tool and it work so well I just had to share it with my fellow makers.
I considered holding back the reflowR campaign until I complete the Many-maker but I don't think it will interfere too much as the reflowR is not a complicated machine, not like the Many-maker.
As it stands now I am using a basic reflowR in my day to day tasks, all the PID functions, profiling and and WiFi connectivity is almost complete for my many-maker project, but it is a trivial task to port it to the reflowR. So the risk of the project failing is really very low.
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With your help I hope to to raise enough support and enough volume to have the reflowR readily available at low cost to makers, teachers, learners and professionals from a USA based fulfillment partner such as Redstag.
Funding goals:
This is a "fixed funding" project so if I do not receive the needed support the project will be cancelled and you will be refunded so please spread the word and help make this happen.
$5 000 This is my "market demand test", if I cannot reach this goal then there must be no real need.
$20 000 Stretch goal - Engage a USA based fulfillment partner such as Redstag to enable rapid local delivery.
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My name is Lafras, a lifelong tinkerer, maker and sometimes inventor, but mostly an analyst programmer (developer as we are known these days). I have been a self-employed entrepreneur for the last 23 years, I own a beautiful home with my wife and I live and work in wonderful KZN, South Africa.
Right from childhood I have always loved building stuff for myself, to share and sell, but budget and availability of parts was always a problem, until I discovered programming, On my
ZX81 (
a.k.a. Timex Sinclair 1000) I could create anything in 1KB RAM, share it with friends and all it cost was a cassette tape, Professional programming has been my life, but now I am rediscovering the joys of making and choosing my own projects.
Inventor reborn. My story is not unique, and I am sure you feel the same way, together we can make more things, many many more things.
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Even If you are not interested in working with electronics yourself, Your kids, family and the next generation can be inspired by the practical and awesome effect of working hands on with technology to pursue higher education, So please share this project with all your friends using the Indiegogo share buttons.
Many thanks
Lafras
