Instructables Robot PCB

Hello everyone!

In this instructable, I am going to show you how to create a PCB of our cute Instructables robot!

I will show you how to create it using the PCB software called Eagle and making a little circuit with LEDs and resistors.

At the same time we learn how to make a PCB, once it is finished and produced in a factory of our choice, we will be able to solder the components on the PCB and, for those who are starting this hobby, it will be a great start because of the simple and easy-to-solder components used.

Are you ready? Keep reading!

Step 1: Parts and Tools

• Custom, Instructables robot-shaped PCB manufactured at JLCPCB.
• 1 x 5mm red LED
• 1 x 3mm red LED
• 2 x resistors
• 1 x CR2032 Battery holder

Tools needed:

Soldering iron

Eagle software

Black marker pen

Step 2: Creating the Board in Eagle

In this first step, I am going to show the process to create this awesome robot board from scratch using Eagle software.

First of all, we have to create the outline of the robot using an image editing software. To do this I used a colour image of the robot. Note that I have removed the antennas. Keep reading and you will know what is going to happen to them! We want to save it as a .BPM file. Once we have this, we have to import this outline to the PCB software.

To import this outline we are going to use the import tool. Search File>Import>Bitmap. Follow the instructions, select a size and press OK.

After a few minutes, we have the outline imported. As you may see the layer we imported is a BMP layer. To create the black outline and all the details on the robot we are going to change the layer to tPlace. To do this simply select all, click on the wrench symbol and select "layer". Here we need to find and select the tPlace layer. Then right-click anywhere and "Change: Group"

Done! In the finished board, this is going to be our Top Silkscreen (white). This layer has the outline and all the details such as eyes, chest buttons, fingers...

Now, to have a bottom silkscreen as well we are going to select everything, copy it and change the layer to bPlace. Once we have done this, we are going to overlap both layers. Make sure they match!

After this, we need to create a board outline. This is going to be the actual shape of our board. To do this, we need to select the "line" tool and change the layer to "Dimension". Now we can start drawing the outline. We have to follow the drawing we already have.

Done! we have the basic board shape and in the following steps, I will cover how to create the circuit and some other details I have included.

Step 3: Creating the Circuit

For this PCB, I wanted a simple circuit and something that could go well with the design so I thought about putting two red LEDs to be his eyes. To power a LED we will need resistors and a battery holder as well.

These two components are going to be at the back (bottom layer) so the top layer (the front) is going to be clear and we can see a clean design.

So, to create a circuit, first, we need to add the components. Click on the "Add" tool and search for the components. Once we have them, place them on the board. In this case, the two LEDs go in his eyes (top layer) and the resistors and the battery holder go at the back (bottom layer). I used two pads for the resistors because I don't want to use through holes and spoil the top layer design so I am going to used normal through holes resistors but I will solder them to these pads. Keep reading to see it!

Once we have placed the components we are going to close the circuit with copper traces. I created a parallel circuit with two LEDs and two resistors that are powered by the same 3v battery (to make it more portable).

Simply connect all the components. Make sure the layer you have selected for the "lines" is the bottom one.

Step 4: Adding Some Details

In this step, I am going to explain how to add some details to your boards and in this case to make it look like the real Instructables Robot

As you may have noticed, our beloved Robot has two antennas in his ears. As I didn't want this to be made of PCB I thought that I could solder some resistor legs and bend them to look like real antennas. So to achieve that, I just planned two holes in his ears. These holes are called "Vias", select them and put them in the ears of your robot. I copied the same measures of the vias in the LEDs so they are exactly the same. This way, the resistor legs can be soldered there and act as antennas!

Secondly, our Robot has steel wheels. So to recreate this in the PCB I used the layer "tStop" because this layer tells the PCB company not to add Soldermask. So the grey lead surface is visible and this way we can recreate the steel wheels! Isn't that amazing? To make this, select the tool "Polygon", then select the "tStop" layer. Now we just have to create a polygon following the design of the wheels. Do this in both wheels.

To make it look more as a robot, I also used this technique with the 5 little bolts and 3 buttons he has in his body. so instead of being white (colour of the silkscreen) they will be grey as steel!

To do this, we just need to create a polygon or replace the layers with the before mentioned "tStop" layer.

Finally, to make the board look more professional, I created two polygons covering all the board with the layers "Top" and "Bottom" so they will not need to etch all the copper away. Instead, they will etch the copper around the circuit and that is all.

Now we have our fantastic board and we just have to convert it to Gerber files to send it to the PCB manufacturer. For this, we are going to open a CAM processor, select the job we normally use and press on "process job". We will have to wait a bit and then we will have some different files with different file extensions. Zip them all together and let's upload them to our favourite PCB manufacturer, in this case, JLCPCB.

If you want more information on how to convert your eagle file to gerbers, please check this link out. It is very well explained here.

If you do not want to make the board from scratch, I will leave the gerbers for you to download. Remember this is for personal use and you must credit the author.

Step 5: PCBs Are Here!

For this Instructable, I have used my favourite PCB manufacturer. JLCPCB

JLCPCB offers 5 custom PCBs for just $2! It is very convenient for small prototypes or even large because their prices are really good and their service is even better. They have fast turnaround times, cool colours such as the yellow on this PCB and great customer service. Many thanks to JLCPCB for sponsoring this project. You should check it out!

If you just want one of these fantastic boards, just DM me and see if we can work it out!

Once we have received the amazing boards, we can start soldering!

As I said, I wanted to make this project as simple as possible so that absolute beginners can also make it. It will be a great practice for those who are starting in this hobby.

Step 6: Soldering the Back Components

Before starting soldering, I used a black marker to simulate the black outline of the robot because it is white now so you can do the same or leave it white as it is. Both look incredible.

First, we are going to solder the components in the back, so grab the battery holder and the resistors and solder them in place.

After this, flip the board and solder the LEDs. As you can see one eye is bigger than the other, that's why I chose 5mm and 3mm LEDs to make the board as similar as our robot! Remember to check the polarity! Now solder them and cut the legs. Finally, with the legs we have cut from the resistors or the LEDs, we are going to make the antennas. Simply bend the leg and solder it in place. One in each ear.

Step 7: Finished!

Congratulations! We have made the Instructables Robot board!! Now just insert a CR2032 3V battery and enjoy! (when the LEDs are on they look different but it is just a camera effect. Yours will look the same!)

You can also add an adhesive brooch clip and wear it!

I hope you liked this instructable as much I liked creating the board and explaining how to do it here as well.

Enjoy your Instructables Robot Board and don't forget to vote me in the PCB Contest!

See you in the next Instructable!