Flux Blog

News, resources, and company updates

AI Auto-Layout Just Got Smarter

Today, we’re excited to share our Summer Update to Flux AI Auto‑Layout, a collection of improvements designed to make one‑click PCB routing more reliable, transparent, and adaptable to your real‑world workflows.

|
July 31, 2025
Thank you! Your submission has been received!
Oops! Something went wrong while submitting the form.
Introduction to the ATtiny85 Microcontroller

Introduction to the ATtiny85 Microcontroller

From programming to hardware connections, this ATtiny85 comprehensive guide provides everything you need to know to get started. Read on and start exploring the endless possibilities of this tiny yet mighty microcontroller.

| ATtiny85 Features | | | :=== | :=== | | No. of Pins | PDIP: 8pins / QFN: 20pins | | CPU | RISC 8-Bit AVR | | Operating Voltage | 1.8 to 5.5 V | | Program Memory | 8K | | Program Memory Type | Flash | | RAM | 512 Bytes | | EEPROM | 512 Bytes | | ADC Number of ADC Channels | 10-Bit 4 | | Comparator | 1 | | Packages | PDIP(8-Pin) SOIC(8-Pin) TSSOP (8-Pin) QFN/MLF (20-Pin) | | Oscillator | up to 20 MHz | | Timer (2) | 8-Bit Timers | | Enhanced Power on Reset | Yes | | Power Up Timer | Yes | | I/O Pins | 6 | | Manufacturer | Microchip | | SPI | Yes | | I2C | Yes | | Watchdog Timer | Yes | | Brown out detect (BOD) | Yes | | Reset | Yes | | USI (Universal Serial Interface) | Yes | | Minimum Operating Temperature | -40 C | | Maximum Operating Temperature | 125 C |

Does ATtiny85 have analog pins?

Yes, ATtiny85 has two analog input pins, namely PB2 (ADC1) and PB3 (ADC3). These pins can be used to read analog signals from external sensors or other devices. It's one of the key features of the ATtiny85 is its analog input pins, which enable it to read analog signals from external sensors or other devices. This makes it suitable for applications that require high precision, such as temperature sensing and audio processing.

The analog-to-digital converter (ADC) in ATtiny85 has a resolution of 10 bits, which means that it can convert analog signals into digital values with a range of 0 to 1023. This makes it suitable for applications that require high precision, such as temperature sensing and audio processing.

How many bits is ATtiny85?

ATtiny85 is an 8-bit microcontroller, which means that it can process data in 8-bit chunks. This limits the range of values that it can process, but also makes it more efficient and less power-hungry than 16-bit or 32-bit microcontrollers.

The 8-bit architecture of ATtiny85 means that it can perform simple arithmetic and logic operations quickly and efficiently. However, it may not be suitable for applications that require complex mathematical calculations or high-speed data processing.

Is ATtiny85 a microcontroller?

Yes, ATtiny85 is a microcontroller. It is a small, integrated circuit that contains a processor core, memory, and a variety of peripherals. It is designed to be used in embedded systems and can be programmed to perform specific tasks.

The microcontroller architecture of ATtiny85 makes it ideal for use in applications that require real-time processing, such as sensor data acquisition, motor control, and audio processing. It is also suitable for applications that require low power consumption and a small form factor.

This module comes with software select power saving modes that are very helpful for the applications that operate with minimum power.

Like other controllers introduced by the Microchip, this module comes with 10-bit ADC converter that houses 4 analog channels that help in sensor interfacing and converting analog signals to digital ones.

This tiny chip is available in four packages called PDIP, SOIC, TSSOP, and QFN where first three come with 8-pin interface while the last one contains 20 pins.

Mini development board: ATtiny85 can be used as small development board which is a great way to jump into microcontroller electronics.

ATtiny85 Main Core Functions

ATtiny85 can perform a number of functions on a single chip. Some pins come with an ability to employ more than one functions.

Timers

One of the powerful features of the ATtiny85 microcontroller is its ability to function as a timercounter.. The ATtiny85 has two 8-bit timers (Timer0 and Timer1) that can be used for a variety of timing applications. These timers can operate in several different modes, including:

  • Normal mode: In this mode, the timer simply counts up from 0 to 255 and then starts over. This mode is useful for generating delays and for basic timing applications.
  • CTC (Clear Timer on Compare) mode: In this mode, the timer counts up to a specified value and then resets to 0. This mode is useful for generating precise delays and for measuring time intervals.
  • PWM (Pulse Width Modulation) mode: In this mode, the timer generates a square wave with a variable duty cycle. This mode is useful for controlling the speed of motors and for generating audio signals.

In addition to the timers, the ATtiny85 also has a built-in watchdog timer that can be used to reset the microcontroller if it becomes stuck or unresponsive. This feature is especially useful in safety-critical applications where the microcontroller needs to be able to recover from errors and prevent system failures.

SPI Communication

ATtiny85 comes with a serial peripheral interface (SPI) that is mainly used for communication between the microcontroller and other peripheral devices such as SD cards, sensors, and shift registers. It incorporates separate clock and data lines with the addition of a select line to pick the required device for communication. This communication allows both connected device to lay out the same path of communication under one communication protocol.

I2C Communication

I2C protocol is added in the device that is mainly two-wire protocol used to connect low-speed devices like ADC and DAC converters, I/O interfaces and microcontrollers. The two wires, known as Serial Clock (SCL) and Serial Data (SDA), are the main part of this communication protocol. The SCL line behaves like a clock signal that is generated by the master device and synchronizes the data transfer between the devices. While the SDA line is used to carry the required data.

BOD or Brown out reset

The BOD is a very useful function that helps in resetting the controller once the Vdd (voltage supply) drops below a brownout threshold voltage. The multiple voltage ranges are provided to secure the module once the power drops at the voltage supply line.

Interrupt

The interrupt plays a vital role in an emergency which puts the main function on hold and executes the required instructions that are necessary at that time. Once the interrupt is executed the running code puts the controller back to the main program.

ADC Converter

ADC module is a valuable addition in the device that makes it compatible with the sensors. It is a 10-bit module that contains 4 channels which are little less than the number of channels available on the modules introduced by Microchip that, more or less, come with 7 or 12 channels.

Microphone sinewave dislay: ATtiny85 can be used to generate and manipulate sound in various audio applications.

In addition to these applications, ATtiny85 can also be used in various DIY projects, hobbyist electronics, and educational projects. Its simplicity and ease of use make it a great choice for beginners who are learning about microcontrollers and embedded systems.

ATtiny85 available packages

The ATtiny85 comes in various packages, including:

  1. 8-pin DIP (Dual Inline Package): This is the most common package for the ATtiny85, and it has 8 pins that can be inserted into a breadboard or socket.
  2. 8-pin SOIC (Small Outline Integrated Circuit): This package has the same pinout as the DIP package, but it is smaller and designed for surface-mount applications.
  3. 8-pin MLP (Micro Leadframe Package): This is a surface-mount package that is even smaller than the SOIC package.
  4. 20-pin QFN (Quad Flat No-Lead): This package has a low profile and no leads, which allows for high-density circuit designs.

ATtiny85 Pinout

ATtiny85 PDIP-8 Package Pinout

Following table shows the pin description that will help you understand the major functions associated with each pin.

| Pin# | Name | Description | | :== | :== | :== | | 1 | PB5 PCINT5 RESET ADC0 dW | I/O Bidirectional pin Interrupt Reset Analog Channel 0 Define Word | | 2 | PB3 PCINT3 XTAL1 CLKI OC1B ADC3 | I/O Bidirectional pin Interrupt Crystal Oscillator Pin 1 Clock Analog Channel 3 | | 3 | PB4 PCINT4 XTAL2 CLKO OC1B ADC2 | I/O Bidirectional pin Interrupt Crystal Oscillator Pin 2 Clock Analog Channel 2 | | 5 | PB0 MOSI DI SDA AIN0 OC0A OC1A AREF PCINT0 | I/O Bidirectional pin SPI Serial Data (I2C) Analog Input Compare Register Voltage Reference Interrupt | | 6 | PB1 MISO DO AIN1 OC0B OC1A PCINT1 | I/O Bidirectional pin SPI Serial Data (I2C) Analog Input Compare Register Interrupt | | 7 | PB2 SCK USCKSCLADC1T0 PCINT2 | I/O Bidirectional pin Serial Clock Line (I2C) Analog Channel 1 Timer 0 Interrupt | | 4 | GND | Ground Pin | | 8 | VCC | Voltage Supply Pin |
ATtiny85 QFN-20 Package Pinout

ATtiny Memory

The memory of this little toy is designed and based on Atmel's high-density technology that is basically non-volatile in nature. The Program Memory can be reprogrammed through SPI serial interface using two ways i.e. On-chip boot code or non-volatile memory programmer. The main program execution is mainly done inside CPU that plays a vital role to access memories and perform calculations on the basis of the number of instructions incorporated into the controller. This module falls under the category of AVR controllers that are based on Harvard architecture and come with separate locations reserved for both program and data memory.

  • ROM Read only memory: The ATtiny85 microcontroller has a total of 8KB of flash memory for storing program code. This memory is non-volatile, which means that it retains its contents even when power is removed from the device. The flash memory is organized into 8K bytes, with each byte being individually addressable.
  • RAM Random access memory: In addition to flash memory, the ATtiny85 also has 512 bytes of SRAM (Static Random Access Memory), which is used for storing data during program execution. Unlike flash memory, SRAM is volatile, which means that it loses its contents when power is removed from the device.
  • EEPROM: The ATtiny85 also has 512 bytes of EEPROM (Electrically Erasable Programmable Read-Only Memory), which is non-volatile memory that can be used for storing data that needs to be retained between power cycles. EEPROM memory is accessed using special instructions and is slower than SRAM, but it can be written to and erased multiple times without wearing out.
LED controllers: ATtiny85 can be used to control the brightness and color of LEDs in various lighting applications.

How do I upload codes to ATtiny85?

To upload codes to ATtiny85, you need a avr programmer device that can communicate with the chip. There are several programmer devices that are compatible with ATtiny85, such as USBasp, Arduino as ISP, and Atmel AVRISP mkII.

Once you have the programmer device, you can connect it to your computer and the ATtiny85 chip using a breadboard or a custom PCB. You will also need to install the appropriate software, such as AVRDUDE or the Arduino IDE.

To upload the code to ATtiny85 using AVRDUDE, you will need to enter the appropriate commands in the command prompt or terminal window. For example, the command to upload a hex file to ATtiny85 using USBasp would be: 

avrdude -c usbasp -p attiny85 -U flash:w:myprogram.hex

There are many compilers available for compiling the code in the AVR microcontroller. Some are better than others. Before you pick some compiler for your controller, make sure it is easy to use and stand fit for your needs and requirements.

  • ImageCraft is good option to start with that has made a decent place in the market but lack of GUI features make this compiler difficult to handle where editor and project management are quite daunting and can put you in a total stall in the start.
  • CodeVision is another easiest compiler that comes with CodeWizard and helps in starting a new project sooner than later. Also, it is highly economical.

Alternatively, you can use the Arduino IDE to upload the code to ATtiny85. To do this, you will need to install the ATtiny core for Arduino and select the appropriate board and programmer settings. You can then write your code in the Arduino IDE and upload it to ATtiny85 using the standard upload button.

Tiny Motor Control board: ATtiny85 can be used to control the speed and direction of small motors in robotics and other applications.

Connecting ATtiny85 with Arduino uno as your programmer

| Arduino Pin | ATtiny85 Pin | | :== | :== | | 10 | 1 | | 11 | 5 | | 12 | 6 | | 13 | 7 | | +5V | 8 | | GND | 4 |

Tiny things can work wonders if used a proper way. Both ATtiny85 and Arduino uno, when connected, can easily drive automation in your project and help in executing the number of instructions. You can connect ATtiny85 with the Arduino following way.

It is important to note that programming ATtiny85 can be a bit challenging for beginners, as it requires some knowledge of electronics and programming. However, there are many tutorials and resources available online that can help you get started. Once you get the hang of it, programming ATtiny85 can be a fun and rewarding experience.

In conclusion, the ATtiny85 microcontroller is a versatile and powerful device that packs a lot of functionality into a small package. Despite its modest size, it is capable of running a wide range of applications and can be used in projects that require real-time processing, low power consumption, and a small form factor.

Whether you are a beginner who is just getting started with microcontrollers or a seasoned professional looking for a compact and efficient solution for your next project, the ATtiny85 is definitely worth considering. With its analog input pins, 8-bit architecture, and built-in flash, SRAM, and EEPROM memory, it provides a good balance of features that make it suitable for a wide range of applications.

So, if you are looking for a microcontroller that is small, efficient, and powerful, be sure to check out the ATtiny85. With its simplicity and ease of use, it is a great way to get started with embedded systems and explore the world of microcontrollers.

For more details and specifications, check out ATtiny85 Datasheet.

|
March 11, 2023
Raspberry Pi Zero 2 W Review: a Powerful and Affordable Mini Computer

Raspberry Pi Zero 2 W Review: a Powerful and Affordable Mini Computer

The Raspberry Pi Zero 2 W is a small and powerful computer with impressive performance for its size and price. With a quad-core processor, 512MB of RAM, built-in wireless connectivity, and a USB On-The-Go port, it's suitable for many projects, including home automation, media centers, and robotics.

What can I do with Raspberry Pi Zero 2 W?

The possibilities are endless, but here are a few popular use cases:

  1. DIY projects. The RPi Zero W's compact size and low power consumption make it ideal for DIY projects. You can use it to build a retro gaming console, a smart mirror, or even a robot. The GPIO (General Purpose Input/Output) pins allow you to connect sensors, motors, and other components to create your own custom hardware.
  2. Learning to code. The RPi Zero W is a great tool for learning programming and electronics. With its low price point and user-friendly interface, it's accessible to beginners who want to start learning how to code and play around with basic electronics. There are plenty of resources available online to help you get started, from tutorials on programming languages like Python to projects that show you how to build simple to advanced circuits.
  3. Home automation. The Raspberry Pi Zero W can also be used to build a home automation system. With its built-in wireless connectivity, you can control your home's lighting, heating, and other appliances using your smartphone or computer. You can use popular platforms like Home Assistant or OpenHAB to set up your own custom automation system. With its micro-hdmi port, you can use a hdmi adapter and hdmi cable to display important data and metrics on a 1080p30 resolution monitor.
  4. Portable computing. The Raspberry Pi Zero W's small size and low power consumption make it perfect for portable computing. You can build a handheld computer that runs on battery power and has a built-in display. With the addition of a keyboard and mouse, you can use it as a fully functional computer for basic tasks like browsing the web, checking email, or writing documents.
  5. Internet of Things (IoT). The Raspberry Pi Zero W is a popular choice for building IoT projects. With its wireless connectivity and GPIO pins, you can connect sensors, cameras, and other devices to the internet and collect data in real-time. You can use this data to automate tasks or create custom alerts and notifications.

The Raspberry Pi Zero 2 W has a USB On-The-Go (OTG) port, which allows it to act as a USB device or host. You can connect the Raspberry Pi Zero 2 W to another device, such as a computer, and use it as a USB device (act as a flash drive) or use the Raspberry Pi Zero 2 W to control USB devices or peripherals connected to it (such as a keyboard or mouse).

  • As a USB device, you will need a USB OTG cable which connects to the USB port on the Raspberry Pi Zero 2 W and provides a USB Type-A port for connecting to the host device.
  • As a USB host, you can connect USB devices directly to the USB OTG port on the Raspberry Pi Zero 2 W. However, because the Raspberry Pi Zero 2 W has a limited number of USB ports, you may need to use a USB hub to connect multiple devices.

Is Raspberry Pi Zero 2 W fast?

With its quad-core ARM Cortex-A53 processor running at 1GHz. It has 512MB of LPDDR2 RAM, and it supports wireless connectivity with built-in 2.4GHz and 5GHz Wi-Fi and Bluetooth 5.0. It also has a microSD card slot, a micro-HDMI port, and a USB Type-C port for power and data.

Compared to its predecessor, the Raspberry Pi Zero W, the Zero 2 W has a significant performance boost. The Zero W had a single-core ARMv6 processor running at 1GHz and only 512MB of RAM. The Zero 2 W's quad-core processor and LPDDR2 RAM make it much faster and more capable of handling more demanding applications.

In terms of benchmarks, the Raspberry Pi Zero 2 W is faster than its predecessor and other single-board computers in its price range. In tests conducted by The MagPi magazine, the Zero 2 W scored 703 points in the Geekbench 4 benchmark, compared to the Zero W's score of 352 points. This puts the Zero 2 W on par with the Raspberry Pi 3 Model B, which was released in 2016 and is still a popular choice for many projects.

Does Raspberry Pi Zero 2 W have WiFi?

Raspberry Pi Zero 2 W does have built-in WiFi connectivity, which supports the 2.4GHz and 5GHz bands, as well as Bluetooth 5.0. This means that the Raspberry Pi Zero 2 W can connect to wireless networks and Bluetooth devices without requiring additional hardware.

What is the difference between Raspberry Pi Zero and Zero 2 W?

| Feature | Raspberry Pi Zero | Raspberry Pi Zero W | | :--- | :--- | :--- | | Wireless Connectivity | Not included | Includes Wi-Fi and Bluetooth | | SoC | Broadcom BCM2835 | RP3A0 System in Package | | Memory | 512MB DDR2 | 512MB SDRAM | | Price | Less expensive | Slightly more expensive | | Power Consumption | Slightly lower | Slightly higher | | Availability | Less widely available | More widely available | | Pinout | Same pinout| Same pinout |

Raspberry Pi Zero 2 W specification

  • Processor: Broadcom BCM2710B0 quad-core Cortex-A53 (ARM v8) 64-bit SoC @ 1GHz
  • RAM: 512MB LPDDR2 SDRAM
  • Connectivity: 2.4 GHz and 5 GHz IEEE 802.11b/g/n/ac wireless LAN, Bluetooth 5.0, BLE
  • GPIO: 40-pin GPIO header (fully backward-compatible with previous models)
  • Video & Sound: Micro-HDMI port (1080p30 up to 1080p60 video output), MIPI CSI camera connector, 3.5mm audio jack
  • Storage: Micro SD card slot for loading operating system and data storage
  • Input power: 5V DC via USB Type-C connector (minimum 3A), or GPIO header (minimum 3A)
  • Dimensions: 66mm x 30.5mm x 5mm, 9g

Compared to its predecessor which only has Broadcom BCM2835, the Raspberry Pi Zero 2 W has a significantly faster quad-core processor, twice the RAM, and built-in wireless connectivity with support for dual-band Wi-Fi and Bluetooth 5.0. It also has a USB Type-C connector for power and data, instead of the micro-USB port on the previous model. Despite these upgrades, it retains the same small form factor and GPIO header as the original Raspberry Pi Zero. These specifications make the Raspberry Pi Zero 2 W a versatile and powerful single-board computer suitable for a wide range of projects.

What OS (operating system) is Pi Zero 2 W?

The Raspberry Pi Zero 2 W can run a variety of operating systems, just like other Raspberry Pi models. Some of the most popular operating systems that can run on the Pi Zero 2 W include:

  • RaspberryPi OS or Raspbian OS: This is the official operating system for Raspberry Pi boards, including the Pi Zero 2 W. It's a free operation system based on Debian optimized for the Raspberry Pi hardware and comes with a variety of pre-installed software and tools. It can be downloaded from the Raspberry Pi website and is available in both desktop and Lite versions.
  • Ubuntu: Running Ubuntu on your Raspberry Pi Zero 2 W is easy. Just pick the OS image you want, flash it onto a microSD card, load it onto your Pi and away you go.
  • RISC OS Pi: RISC OS is a unique operating system that was originally developed for the Acorn Archimedes computer in the 1980s. It's designed to be secured, fast and efficient, and it's been ported to run on the Raspberry Pi. RISC OS has a unique user interface and comes with a variety of software and tools.
  • RetroPie: RetroPie is a popular operating system that turns the Raspberry Pi Zero 2 W into a retro gaming console. It includes a variety of emulators and game engines, and it supports a wide range of classic game consoles and systems.
  • Other Linux distributions: The Raspberry Pi Zero 2 W can run a variety of other Linux distributions, including Arch Linux ARM, Fedora, and Gentoo. These distributions may require more advanced setup and configuration compared to the more user-friendly options like Raspberry Pi OS and Ubuntu.

Things You Should Know Before Buying RPi Zero 2 W

  1. Purpose: The Raspberry Pi Zero 2 W is a small and powerful computer, suitable for a range of projects, such as home automation, robotics, and media centers. Before purchasing, consider what you plan to use it for to ensure it meets your requirements.
  2. Price: While the Raspberry Pi Zero 2 W is affordable, it is more expensive than the previous Raspberry Pi Zero models. You should be prepared to spend a little more for the added features and performance.
  3. Connectivity: The Raspberry Pi Zero 2 W has built-in wireless connectivity (WiFi and Bluetooth), which is convenient for many projects. However, it also has a limited number of USB ports and no Ethernet port, which can be a consideration for some projects.
  4. Power Requirements: The Raspberry Pi Zero 2 W requires a 5V power supply capable of providing at least 3A of power, which may be different from the power requirements of other Raspberry Pi models.
  5. Availability: The Raspberry Pi Zero 2 W has been in high demand since its release, which can make it difficult to find in stock. Be prepared to search for it or consider pre-ordering to ensure you get one when it's available.

By considering these factors, you can determine if the Raspberry Pi Zero 2 W is the right choice for your project and be prepared to get started with it once you have it in hand.

Want to get started now? Here's a simple (Hardware attached on top) HAT template you can use for your Raspberry pi zero 2 W.

|
February 25, 2023
How to Convert from MM to Mils: a Guide for Beginners

How to Convert from MM to Mils: a Guide for Beginners

The guide provides an easy-to-follow formula for converting mm to mils, essential in engineering and PCB design for precise measurements and applications.

The Metric System vs. the Imperial System

Before we discuss how to convert MM to mils, it's essential to mention the metric system and the imperial system. 

  • The metric system is used worldwide and employs units like milliliters, centimeters, and millimeters. 
  •  The imperial system is more common in the United States, employing units like fluid ounces and inches. 

Our focus is on mm, a metric unit, and its conversion to mils, an imperial unit.

The Basics: Millimeters and Mils

  • Millimeters, denoted as "mm," are a metric unit that is one-thousandth of a meter, or 0.001 meters.

What units are mils?

  • Mils are one-thousandth of an inch, meaning 1 mil is equivalent to 0.001 inches.

However, mils are sometimes used in a different context as milliradians (mils), which are units of angular measurement commonly used in ballistic calculations and optical instruments.

mm to mils Conversion Formula

To convert from millimeters to mils, you can use the following straightforward conversion formula:

Mils = Millimeters * 39.37

We can derive this formula the following way:

  • 1 inch equals 25.4 millimeters (2.54 centimeters)
  • 1 mil equals 0.001 inch
  • So, 1 mil equals 0.0254 mm.
  • And 1 mil divided by 0.0254 mm is 39.37 mils per mm
  • Therefore, multiplying millimeters by 39.37 gives us the equivalent measurement in mils.

Let's illustrate this with an example: Suppose you have a measurement of 0.5 mm and want to convert it to mils:

Mils = 0.5 mm * 39.37 ≈ 19.685 mils

So, 50 millimeters is approximately 19.685 mils. That's about the thickness of two business cards!

Mils to mm 

This conversion is essentially the reverse of our previous equation. You can use the following straightforward conversion formula:

Millimeters (mm) = Mils / 39.37

Let's walk through an example of converting from mils to millimeters using the conversion formula:

Suppose you have a measurement of 50 mils, and you want to convert it to millimeters. You can use the formula as follows:

Millimeters (mm) = 50 mils / 39.37 ≈ 1.27 mm 

So, 50 mils are approximately equivalent to 1.27 millimeters. That's about the thickness of a U.S. Dime!

How thick is 1 mil in mm?

1 mil = 0.0254 Millimeter

Conversion Chart

For those who prefer visual aids, having a conversion chart on hand is common. Here's a short conversion chart we made to give you an idea:

| Mils | Millimeters (mm) | | :=== | :=== | | 10 | 0.254 | | 20 | 0.508 | | 30 | 0.762 | | 40 | 1.016 | | 50 | 1.270 | | 60 | 1.524 | | 70 | 1.778 | | 80 | 2.032 | | 90 | 2.286 | | 100 | 2.540 | | 120 | 3.048 |

In this chart, we have provided conversions for mils ranging from 1 to 120. This should cover most conversion needs. However, if you require conversions for values outside this range, simply use the conversion formulas mentioned earlier.

Why Convert to Mils in Electrical Engineering?

Mils are frequently employed in precision applications in the US, where small measurements are crucial. Below are specific scenarios where mils come into play for electrical engineers:

  1. Printed Circuit Boards (PCBs): Electrical engineers often use mils to specify the spacing between components and the traces on a PCB. For example, a common requirement for PCB trace spacing to prevent electrical interference is 6 mils (0.1524 mm). This level of precision ensures that signals do not cross over and disrupt the proper functioning of the circuit.
  2. Component Sizing: SMT (Surface Mount Technology) components often have specific pad sizes and pitches specified in mils. Engineers ensure that components fit snugly and securely on the PCB, reducing the risk of manufacturing errors or circuit malfunctions. Standard component pad sizes for SMT components can range from 20 mils (0.508 mm) to 40 mils (1.106 mm), depending on the component and its intended use.
  3. Wire Gauge Measurements: The American Wire Gauge (AWG), a U.S. standard for wire conductor size, relates to the diameter of the wire in mils. For example, typical household copper wiring is AWG number 12 or 14, translating to 12 or 14 mils in diameter.

For SMT components in PCB design, there are part size references that are commonly used and are crucial for specifying dimensions on the PCB. This table provides their size values in both mils and millimeters for easy reference during PCB design and assembly:

| Imperial Part Size Reference | Size in Mils | Size in Millimeters | Metric Part Size Reference | | :=== | :=== | :=== | :=== | | 0201 | 20 mils | 0.508 mm | 0603 | | 0402 | 40 mils | 1.016 mm | 1005 | | 0603 | 60 mils | 1.524 mm | 1608 | | 0805 | 80 mils | 2.032 mm | 2012 | | 1206 | 120 mils | 3.048 mm | 3216 |

Don't be Confused! Understanding the Milliradian "Mil"

We've mentioned milliradians earlier, so let's clarify what they are. A milliradian, often denoted as "mrad" or "mil," is a unit of angular measurement. It is used in various fields, including ballistics and engineering. When you hear talk about a mil-dot scope or mil reticle, it's referring to measurements in milliradians. In this context, one radian is divided into 1,000 milliradians, and the reticle markings are spaced at one milliradian intervals.

|
November 15, 2023
Explore the Advantages of Buck and Boost Converter in Modern Electronics

Explore the Advantages of Buck and Boost Converter in Modern Electronics

Buck and Boost converters are highlighted for their power efficiency and system reliability roles. The blog reveals their unique advantages, making them essential in diverse applications like renewable energy and portable electronics.

Buck Converter: The Inductor-Driven Step Down Marvel

A simplified circuit diagram of a buck converter or step-down converter
Buck Converter Topology

Principle of Operation

A Buck converter serves as a step-down DC-DC converter, adept at transforming a higher input voltage to a lower, regulated output voltage (Vout). The core components include an inductor, a diode, a switch (commonly a MOSFET), and a capacitor. By modulating the pulse-width modulation (PWM) duty cycle of the MOSFET, the Buck converter fine-tunes the Vout.

Advantages

  1. High Efficiency: Buck converters excel in recycling excess voltage through the inductor, achieving efficiencies often above 90%.
  2. Minimal Heat Dissipation: The high-efficiency operation of the Buck converter inherently curtails heat generation, mitigating the need for heat sinks or other cooling systems.
  3. Broad Input Voltage Spectrum: These converters can handle a wide array of input voltages, making them versatile in diverse applications like solar power systems and automotive electronics.
  4. Swift Transient Response: The Buck converter's rapid transient response to changes in load or input is a crucial asset in real-time applications.

Boost Converter: The Voltage-Elevating Specialist

A simplified circuit diagram of a boost converter or step-up converter
Boost Converter Topology

Principle of Operation

In contrast to the Buck converter, a Boost converter acts as a step-up DC-DC converter. It elevates a lower input voltage to a higher Vout. The essential components—inductor, diode, MOSFET, and capacitor—are arranged differently to achieve this function.

Advantages

  1. Voltage Amplification: Boost converters can significantly elevate the input voltage, making them invaluable in low-voltage applications like photovoltaic systems.
  2. Compact Footprint: The inductor-centric design of the Boost converter allows for a more compact form factor compared to transformer-based solutions.
  3. High Efficiency: Similar to Buck converters, Boost converters also maintain high efficiency, particularly when the voltage differential is minimal.
  4. Inrush Current Limitation: The inductor inherently restricts inrush current, adding an extra layer of system protection.

The Versatility of Buck-Boost and Sepic Converters

For systems that require both step-up and step-down voltage regulation, Buck-Boost and Sepic (Single-Ended Primary Inductor Converter) converters offer a flexible solution. They can function as either a Buck or a Boost converter, depending on the input voltage and system demands.

Special Mention: Flyback and Inverting Converters

Flyback converters are useful for applications requiring isolated outputs, while inverting converters can invert the polarity of the output voltage, expanding the range of potential applications.

The Significance of These Converters in Modern Electronics

  1. IoT Devices: The Internet of Things (IoT) is burgeoning, and with it comes the need for low-power, high-efficiency devices—perfect candidates for Buck and Boost converters.
  2. Electric Vehicles (EVs): EVs, with their varying voltage levels and subsystems, stand to gain significantly from these power converters.
  3. Renewable Energy Systems: In solar and wind energy setups, where voltage can fluctuate, these converters ensure a stable output for either storage or immediate use.
  4. Portable Electronics: Battery-operated devices like smartphones and laptops benefit from efficient power management, a role well-suited for these converters.

Conclusion

Buck and Boost converters, as specialized DC-DC converters, have become irreplaceable in the realm of modern electronics. Using simple components and concepts, like inductors, capacitors, MOSFETs, and PWM control, Buck and Boost converters work miracles for power circuits. Their unique advantages in terms of efficiency, versatility, and compactness make them indispensable in shaping the future of power management solutions.

|
September 16, 2023
Discovering PCB Manufacturing: Technologies That Shape the Industry

Discovering PCB Manufacturing: Technologies That Shape the Industry

In this blog, you'll get an insider's look at PCB manufacturing, learn how PCB boards have evolved, and why they're vital in almost every piece of tech you use. We cover all the bases from circuit board printing for basic gadgets to the advanced techniques used by top PCB manufacturers for multilayer boards. The blog also sheds light on upcoming tech that could redefine the industry. It's essential reading for anyone interested in electronics or PCBs.

Evolutionary Milestones in PCB Manufacturing

The industry of PCB manufacturing has undergone significant transformations since its early days in the 20th century. Initially confined to single-sided circuit boards, technological advancements have enabled the development of more intricate double-sided and multilayer PCBs.

The Indispensable Role of PCBs in Modern Technology

In today's technology-driven world, the importance of PCB manufacturing is monumental. These boards are essential for the functionality and reliability of a wide array of electronic systems, making their fabrication a cornerstone of industrial processes.

Categories of PCB Manufacturing

Single-Sided PCB

Understanding and Applications of Single-Sided PCBs

Single-sided PCBs feature only one layer of conductive material, typically copper, and are ideal for low-density designs. These types of circuit boards are prevalent in simple electronic devices like radios and sensors.

Fabrication Process for Single-Sided PCBs

The fabrication involves applying a copper layer on one side of an insulating substrate. The unwanted copper is then etched away, leaving the desired circuit pattern. Soldering components onto the board follows this.

Double-Sided PCB

What Are Double-Sided PCBs and Where Are They Used?

Double-sided PCBs have copper layers on both sides of the substrate, allowing for more complex circuits. These are commonly found in sophisticated devices like smartphones and automotive control systems.

Manufacturing Workflow for Double-Sided PCBs

The process includes applying copper layers on both sides of the substrate and connecting the layers using vias. Soldermask is then applied, followed by the HASL (Hot Air Solder Leveling) or ENIG (Electroless Nickel Immersion Gold) finishing process.

Multilayer PCB

Defining Multilayer PCBs and Their Use Cases

Multilayer PCBs consist of multiple conductive layers, separated by insulating material, and are used in highly complex systems like medical equipment and data servers.

Multilayer PCB Fabrication

The fabrication, or stackup, involves layering multiple sheets of copper and insulating material, which are then pressed together under heat and pressure. Circuit patterns are etched onto each layer, and vias are used to connect them.

Key Stages in PCB Manufacturing

Design and DFM (Design for Manufacturability)

The initial stage involves creating a detailed design of the circuit using CAD software, often incorporating DFM principles to ensure efficient manufacturing.

Substrate Creation and Stackup

The substrate, usually made from materials like FR4 or Polyimide, is fabricated to provide mechanical support to the circuit board. This is followed by the stackup process, where multiple layers are combined.

Copper Layering, Etching, and Finishing

Copper layers are applied to the substrate, and the circuit pattern is etched using chemical processes. The board then undergoes various finishing processes like applying soldermask and silkscreen, followed by HASL or ENIG surface finishing.

The Future Landscape of PCB Manufacturing

Technological Innovations on the Horizon

Emerging technologies like 3D printing and AI-driven optimization are set to redefine the PCB manufacturing sector.

Sustainability and Eco-Friendly Manufacturing

The industry is increasingly focusing on sustainable materials and eco-friendly fabrication processes to mitigate environmental impact.

Challenges and Opportunities

The demand for smaller, more efficient PCB boards presents both challenges, such as material limitations, and opportunities for innovation and technological breakthroughs.

Conclusion

Understanding the intricacies of PCB manufacturing, from the types of PCBs to the key stages in their fabrication, is crucial for anyone involved in the electronics or electrical engineering sectors. As technology continues to evolve, the PCB manufacturing industry is set for transformative developments that will significantly influence the future of electronics.

|
September 1, 2023
The Ultimate Guide to Electrical Connectors and Wiring Connection

The Ultimate Guide to Electrical Connectors and Wiring Connection

This comprehensive guide explores the roles and types of electrical connectors in any wiring project. From crimping tools to wire strippers, it outlines the tools and techniques needed for efficient electrical wiring. The post also provides safety tips and insights into specialized connectors.

Types of Connectors

Wire Connector

Wire connectors come in various types, such as wire nuts, Wago connectors, and crimp connectors. Wire nuts are simple but effective, sometimes used to splice together small AWG (American Wire Gauge) wires. The twist and insulating properties of wire nuts make them popular in residential wiring projects.

Crimp Connectors

Crimping involves placing a metal conductor inside a crimp and using a crimping tool to deform the crimp, enclosing and pressing together the conductor securely. Crimped connections are durable and reliable when done correctly. Crimping is often used for electrical wire splicing and terminal applications.

Solder Connectors

In solder connectors, the conductor is soldered to ensure a robust electrical connection. While soldering requires a soldering iron and solder, the resulting connection is extremely stable and strong. These are common in PCB (Printed Circuit Board) and other high-stake electrical wiring.

Other Types

Wago connectors provide a lever-action to clamp down on the wire. They are often used for stranded wire and offer a reusable solution. DC connectors are used in low-voltage applications and are color-coded for positive (RED) terminal and negative (BLACK) terminal to prevent mistakes.

Key Considerations

Insulation

Insulation is another crucial factor. The insulation around the wire should be stripped using a wire stripper to expose the conductor before using any connector. Insulated connectors provide an extra layer of safety.

Wire Gauge

The gauge wire chosen should match the requirements of the circuit and the connector. Using a wire gauge that's inappropriate can lead to overheating or inefficiency. Can sometimes lead to intermittent connection.

The American Wire Gauge (AWG) is a standard system used primarily in the United States to denote the diameter of electrically conducting wire. The current capacity of a wire varies depending on several factors, such as the insulation type, ambient temperature, and whether the wire is in free air or bundled with other wires.

This table provides a rough estimate of the current-carrying capacity of copper wires with different AWG sizes, typically used for chassis wiring.

| AWG Size | Diameter (mm) | Current (Amps) for Chassis Wiring | | :=== | :=== | :=== | | 0000 | 11.684 | 302 | | 000 | 10.405 | 239 | | 00 | 9.266 | 190 | | 0 | 8.252 | 150 | | 1 | 7.348 | 119 | | 2 | 6.544 | 94 | | 3 | 5.827 | 75 | | 4 | 5.189 | 60 | | 5 | 4.621 | 47 | | 6 | 4.115 | 37 | | 7 | 3.665 | 30 | | 8 | 3.264 | 24 | | 9 | 2.906 | 19 | | 10 | 2.588 | 15 | | 11 | 2.304 | 12 | | 12 | 2.053 | 9.3 | | 13 | 1.828 | 7.4 | | 14 | 1.628 | 5.9 | | 15 | 1.450 | 4.7 | | 16 | 1.291 | 3.7 | | 17 | 1.150 | 2.9 | | 18 | 1.024 | 2.3 |

Conductor Material

Copper is the most common conductor material. The quality of the conductor affects the reliability of the electrical connector.

Voltage Rating and Circuit Breaker

Always consider the voltage and the circuit breaker involved. Incorrectly matched connectors and circuit breakers can result in electrical fires or other hazardous conditions.

How to Use Connectors

  1. Wire Preparation: Use a wire stripper to strip the insulation off the wire ends.
  2. Select Connector: Choose the right electrical connector based on your wiring needs.
  3. Connect Wire: Insert the stripped conductor into the connector.
  4. Secure Connection: Use a crimping tool for crimp connectors, twist the wire nut, or solder for solder connectors.
  5. Test: Always test the electrical connection before incorporating it into your circuit.
  6. Insulate: Finally, use electrical tape or other insulating material to insulate any exposed wiring.

Safety Tips

  1. Always turn off the circuit breaker before working on any electrical wiring.
  2. Only a qualified electrician should handle complex tasks.
  3. Check for wire connection compatibility and color-coded indications to avoid mismatches.
  4. If you're unsure, consult an electrician.

Specialized Connectors

For data transmission, ethernet connectors are usually used. Junction boxes serve as receptacles for multiple wire connections. For automotive applications, DTL (Deutsch Terminal Lugs) connectors offer robustness against harsh conditions.

Wrapping up

Electrical connectors serve as the backbone for any electrical wiring project. Whether you are splicing, crimping, or soldering, understanding the roles of each connector can make your project efficient and safe. From the humble wire nut to the complex ethernet connector, your choice of connector makes all the difference in ensuring a smooth flow of electricity through your circuit.

So, the next time you take on an electrical project, keep this guide handy to navigate through the complex yet fascinating world of electrical connectors.

Happy Wiring!

|
August 25, 2023