Materials
Before jumping in we'll need to make sure you're prepared. The table below details the different components you'll need to make Pallette. Each item links to where you can obtain it. We left checkboxes so you can keep a checklist of what you have.
| Tools | Parts | Source files |
|---|---|---|
You will need to install the CC Debugger driver and the Bluegiga SDK on a Windows computer or virtual machine, in order to program the Pallette Sensor Ribbon.
Pallette PCBs
PCB manufacturing takes time, so it's better to order the PCBs first. Send the Pallette fabrication zip file inside the hardware design files folder to a PCB manufacturer to receive the Pallette PCBs. You can get a quote here with your desired quantity and turn time. With the fabrication information in the design file, you will get 0.014 inch FR-370HR boards with gold immersion finish, white soldermask, black silkscreen and v-scores, which will be quite pricey (~$100 each for 10 boards and 5-day turn time).
Alternatively, you can get the boards for $33 each with this special deal. However the boards will be 4x thick (FR-4 0.062" material) with lead-free solder finish, green soldermask and white silkscreen. (Photos below feature an older design)
They won't come with v-scores, so you'll have to cut the boards along the thick white lines with a Dremel.
PCB Assembly
To get PCBs assembled, you can either send the PCBs and fabrication zip file to a PCB assembler, or reflow solder the PCBs yourself. The PCB assembler charges the cost based on the quantity of your order, component cost and turn time. (You can get a quote here.) The approximate labour cost for assemble 10 boards at 5-day turn time is around $150 per board; component cost is <$30 per board. On the other hand, if you want to do reflow soldering yourself, you will need to buy electronic components and additional tools:
| Additional materials for reflow soldering |
|---|
This is a Digi-Key cart for 10 boards worth of components. To see the Bill of Materials for one board, click here.
Step 3 will explain how to do reflow soldering in detail. But while you wait for the PCBs to arrive from the manufacturer, you can start making a Pallette device by following the next step - fitting a mouthguard.