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LPKF S100 PCB Prototyper Resources
Links
Grad Instructions for Graduate (Research) use of the Lightning Lab
Documentation
Steps Basic steps for producing a PCB in the Lightning Lab.
Poster How to make a PCB with plate-through holes & vias.
Manual LPKF S100.
Manual CircuitCAM-Lite (Version 5) is pre-processing software that converts your Gerber files (generated by Altium) into an LMD file which is what you take to the S100 to make your circuit board. A simple version (CircuitCAM Lite - Version 5) of this software is pre-loaded on all undergraduate computers. It can also be installed on any other computer in the department. Contact help@ece.ubc.ca for more information.

The full version (CircuitCAM - Version 6) is only available on the control computer in the prototyping lab.
Manual BoardMaster - controls the S100 to create a physical PCB from an LMD file.
PDF Tutorials
Tutorial Importing a layout using CirciutCAM.
Tutorial Using ProConduct for through-hole plating
Video Tutorials
   
Tutorial Startup and initialization of the S100.
Tutorial Using the S100 to make a PCB.
Tutorial Using the camera system to register a double-sided PCB.
Tutorial Using ProConduct for through-hole plating
Frequently Asked Questions
Question What Gerber files do I need to import from Altium into CircuitCAM and what must they be set to when I import them?
Answer File Extension Altium CircuitCAM (Layer)
  xxx.gtl
xxx.gbl
xxx.gm1
xxx.txt
Gerber top layer
Gerber bottom layer
Gerber mechanical 1
Drill file		 TopLayer
BottomLayer
BoardOutline
DrillPlated or DrillUnplated
Question What drill sizes are available?
Answer

The stock drill sizes are:

0.8 mm
1.0 mm
1.2 mm
1.5 mm

Make sure that all components and vias use these drill sizes or the drill will not be available in the cartridge when you go to produce the PCB.
Question What are the design rules I must obey when I layout my PCB to get good results?
Answer

8 Mil track widths (~0.2 mm)
8 Mil spacing (~0.2 mm)

It is a good idea to add teardrops (Tools / Teardrops ...)
Question How do I use CircuitCAM to get my files ready for production?
Answer Start up the software and make sure a default (2-sided) board is opened. You should have a black screen. There are 6 big buttons. These correspond to each of the steps you need to take.

Step 1: Import Gerber & Drill files
Import each of the Gerber files listed above (4 or 5, depending on how many drill files you have)
Select the correct description for each file in the Layer / Template column
When each layer appears in the workspace, make sure it looks right

Step 2: Define routing path for separating circuit board from 9x11 blank
For the Source, specify the Layer, "BoardOutline"
For the Tool, specify "Contour Router 2.0 mm (79 mil)"
Press Run (the corresponding router channel will appear)

Step 3: Define breakout tabs
Click on the thick line that appeared after completing the previous step.
Once highlighted, click on a handles where you would like a breakout tab
An asterix will appear
Click on the Breakout Tab Icon
Repeat until you have at least 3 breakout tabs

Step 4: Define rubout area
Click on Define Rubout Area Icon
Click to define bounding box where all copper will be removed
Note that a smaller rubout area will take less time to make

Step 5: Create tool paths
Click on Insulate All Layers icon and tool paths will appear
Make sure none of the tool paths are wiping out any important geometry
Red: Bottom insulation path
Purple: Bottom rubout path
Green: Top insulation path
Blue: Top rubout path

Step 6: Create LMD file
Click on Export icon
CAM file is source file that can be re-opened and editted by CircuitCAM
LMD file is read by BoardMaster to create your PCB on the LKPF S100

Question What is a scratch test?
Answer

The traces on your circuitboard are defined using the 8 Mil Universal Cutter. This tool has a conical tip so the width of the removed material path is determined by how deep it is calibrated to cut. A scratch test simply means making a short test cut using this cutter to see if the gap it leaves is 8 Mil wide.

To perform a scratch test:
Start BoardMaster
Position the tool over a spot on your board where there is room for a 5-10mm cut.
Pick up the Universal Cutter
Turn on the cutting motor
Lower the cutting head
Translate the cutting head by 5-10mm in any direction (into fresh material)
Raise the cutting head
Turn off the cutting motor
Go to the park position and remove your material
Use the microscope to measure the width of the track that you just cut
If it is not 8 Mil, the machine must be adjusted

Note: It is preferrable to have a mill path that is too narrow than one that is too wide. If the path is too wide, the pads and traces on your circuit design will be smaller and in some cases will be removed completely.
Question What exactly is a Mil?
Answer

The S100 is an adaptation of a machinist's tool called a milling machine. Machinists are partial to the SI system of measurement and it is the industry standard.

1 Mil = 1/1000 Inch