Fine-pitch SMD soldering with minimal tools

We try to stick to the 0805 parts because they’re still big enough to solder by hand. But [Scott] shows us that it doesn’t take too many special tools to reflow fine-pitch components at home. In this case he’s using 0402 resistors, a footprint that we consider functionally impossible to solder using an iron.

The two parts of the equation that he spent some money on are professionally produced PCBs and a solder stencil. The stencil is laser-cut from Kapton, which is heat-resistant so it doesn’t warp during the cutting process. An acrylic frame holds the PCB in place, and he just tapes the stencil over it and uses a chunk of acrylic as a squeegee to evenly apply the solder paste. Splurging on the PCB and stencil means you’ll achieve tolerances which lead to success.

The next issue is placing the components. [Scott] shows off some vacuum tweezers he built using an aquarium pump. Watch the video after the break to see how small those 0402 parts are when he extracts one of the resistors from the tape packaging. With the board manually populated (check everything twice!) he moves the board to a completely unaltered toaster oven for reflow. We have seen a lot of projects which add controllers to these ovens, but he really makes the case that you don’t need it. Instead, he uses a thermocoupler read by a multimeter just to let him know what’s going on with the temperature. He uses a smart phone as a timer, and switches the oven on and off to match the solder’s heat profile. [Read more…]

Toaster oven reflow soldering roundup

SMD components have a lot of advantages over the through-hole parts our fathers and grandfathers soldered. Working with these tiny surface mount components requires a larger investment than a soldering iron and a wire-wrap gun, though. Here’s a few reflow ovens that were sent in over the past week or two.

[ramsay] bought a 110 V toaster oven off of eBay. Even though [ramsay] is in England and has 230 V mains, everything in the oven is mechanical and works just fine with a higher voltage. His first test didn’t go quite as planned; the solder paste wasn’t melting at 120° C, so he cranked up the temperature and learned that the FR in FR-4 stands for flame retardant. Never deterred, [ramsay] decided to build a controller so the temperature ramps up and cools off at the right rates for the flux and paste to do their thing.

Solder paste has a temperature profile that requires the board to be kept at a temperature between 150° and 180° C for a minute or so before climbing up to 220° for a second so the solder will melt. [Nicolas] had the interesting idea of putting a USB port in his toaster oven and storing the heating profiles on his desktop. The build uses an MSP430 microcontroller to turn the relays powering heating elements on and off. [Nick] is working on a C# desktop app to monitor and regulate the oven temperature from his computer, so we’re fairly interested in seeing the final results.

Watching the SMD self-alignment videos on YouTube is a lot more fun than messing around with tweezers, stereo microscopes, and extremely fine soldering irons. If you’ve got a better idea for a toaster/reflow oven, send it in on our tip line and we’ll check it out.

A USB-controlled Solder Reflow Oven

[Joel] of [Helion Microsystems] is at it again with his USB controlled solder reflow oven.  You may remember him from his crazy twitter-enabled Ewok model. Although these two projects are quite different, they both use the HU-320 USB breakout board that he’s in the process of getting funding for via [Pozible], or Australian Kickstarter for Yanks.

The reflow oven works using a thermocouple-enabled RS-232 voltmeter to output the temperature to the HU-320 board. [Joel] has been nice enough to provide us with the C# code to interface with many multimeters if you want to implement a similar project.  Temperature is controlled with a mechanical relay for what would appear to be a poor man’s PID controller.

Sadly, Fluke meters don’t seem to be listed, but your place of work probably wants their meter back anyway!  For another toaster reflow oven implementation, check out this [HAD] article.  Be sure to check out the video after the break for a video of the setup! (heat treat engineers may find the “recipe” format humorous).

[Read more…]