258 lines
11 KiB
Markdown
258 lines
11 KiB
Markdown
TODO: Add table of content
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# MSLA PCB Exposure: KiCad → Photon Mono 4
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## Why MSLA?
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Using an MSLA (Masked Stereolithography Apparatus) resin printer for creating PCBs is a technique known as "Direct UV Exposure." Instead of printing a plastic part, you use the printer's LCD screen as a dynamic digital mask to cure photosensitive materials (etch resist, solder resist and silkscreen) on a copper board.
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The "Matrix LED" ensures uniform light distribution across the entire build area. When exposing a photosensitized board, uneven lighting can cause some areas to be under-exposed (washing away traces) or over-exposed (causing traces to merge). The matrix source ensures the center and corners of your PCB receive the same energy, resulting in a reliable etch.
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## The objective
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KiCad PCB layers need to be converted to `.pm4n` files for direct UV exposure on an **Anycubic Photon Mono 4** (9024×5120 px, 17 µm/px, 1494.12 DPI) on the screen size of 153.408 x 87.040 mm.
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## Hardware
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* A resin 3D printer (e.g., Anycubic Photon Mono 4)
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<img src="images/Anycubic_Photon_Mono4.png" alt="Anycubic Photon Mono 4" width="400"/>
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* Photosensitive PCB. For consistent results, a pre-sensitized board like the **Bungard positive photoresist boards** is highly recommended due to its uniform coating. A good example is [Bungard 160x100 double-sided](https://www.conrad.sk/sk/p/bungard-120306z33-zakladny-material-dvojstranna-35-m-foto-vrstva-pozitiv-d-x-s-160-mm-x-100-mm-1-ks-529176.html) 3,49 €.
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<img src="images/Bungard_PCB.png" alt="Bungard PCB" width="400"/>
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* UV light curing Solder Mask e.g. from Mechanic. Use green as the solder mask and white for the silkscreen.
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<img src="images/Mechanic_UV_Solder_Mask.png" alt="Mechanic UV Solder Mask" width="400"/>
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## Software
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### 1. Install KiCad
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Ensure you have kicad installed:
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```bash
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sudo apt update
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sudo apt install kicad
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```
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### 2. KiCad: Set your design grid (Optional)
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In KiCad's PCB editor, go to `Preferences → Preferences → PCB Editor → Grids` and add a custom grid of 0.017 mm (your MSLA printer's pixel size). This ensures trace edges land on pixel boundaries and avoids the sub-pixel rounding that causes the ±1px size error people see with arbitrary grids.
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### 3. Export gerbers from KiCad
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*If you want to automate the conversion of gerber to printing files, you can jump to the section [Appendix: Automated script](#appendix-automated-script).*
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- Open your PCB project in the KiCad PCB Editor.
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- Go to **File -> Plot** and select `Plot format` as `SVG` and set the `Output directory`.
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- In the `Include Layers` section select layers `F.Cu`, `B.Cu`, `B.Mask` and `F.Silkscreen`. Each layer will be ploted as a separate SVG file.
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- Optionaly, select additional layer(s) e.g. `Edge.Cuts` in the `Plot on All Layers` section. This way you can merge layers i.e. add board outset into each file generated. *This is usually not needed.*
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- Click **Plot** and **Close**.
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<img src="images/KiCad_Plot.png" alt="KiCad Plot" width="500"/>
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### 4. Install `CHITUBOX Basic`
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Follow the [offical installatin guide for Ubuntu](https://docs.chitubox.com/en-US/chitubox-basic/latest/installation#ubuntu)
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### 5. Create the `Dummy.pm4n` file
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Open `CHITUBOX Basic` slicer (or any other slicer that works for your resin printer), select printer **Anycubic Photon Mono 4**, slice any tiny STL (e.g.: 1×1×0.05 mm box), and save as `Dummy.pm4n`.
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This file is reused for every job — it carries the correct LCD resolution metadata.
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## MSLA PCB Exposure
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`UVtools` has a dedicated `PCB Exposure` tool that converts a Gerber file to a pixel-perfect image given your printer's LCD resolution, specifically for exposing copper traces.
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### 1. Install `UVtools`
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- Install `UVtools` dependencies
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```bash
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sudo apt-get install -y curl
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sudo bash -c "$(curl -fsSL https://raw.githubusercontent.com/sn4k3/UVtools/master/Scripts/install-dependencies.sh)"
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```
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- Install `UVtools`
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Grab the Linux release and extract it
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```bash
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LATEST=$(curl -fsSL https://api.github.com/repos/sn4k3/UVtools/releases/latest \
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| grep '"tag_name":' \
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| cut -d '"' -f4)
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wget -P ~/Downloads \
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"https://github.com/sn4k3/UVtools/releases/download/${LATEST}/UVtools_linux-x64_${LATEST}.zip"
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mkdir ~/UVtools
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cd ~/UVtools
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unzip ~/Downloads/UVtools_linux-x64_${LATEST}.zip
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```
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### 2. Run `UVtools`
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```bash
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cd UVtools
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./UVtools
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```
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*To automate the conversion of gerber to printing files, you can jump to the section [Appendix: Automated script](#appendix-automated-script).*
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### 3. Export `.pm4n` file from Gerber layer
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- You export Gerber from KiCad (not SVG), which natively gives you positive/negative control per layer.
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- You open the `Dummy.pm4n` file in `UVtools` (a minimal valid `.pm4n` sliced by `Chitubox` or `Photon Workshop` with any tiny model), then use `Tools → PCB Exposure` to inject your Gerber layer e.g.: `Flow_Controller_Panel-Front.gbr`.
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- You control `inversion`, `invert` and the `exposure time` at the bottom of the `PCB exposure` dialog.
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- You save it as e.g.: `Flow_Controller_Panel-Front.pm4n` file.
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<img src="images/PCB_Exposure_Dialog_2.png" alt="PCB_Exposure_Dialog_2" width="500"/>
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### 4. Check the printer exposure
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Open Chitubox
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```Bash
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cd /opt/CBD/CHITUBOX_Basic
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./CHITUBOX_Basic.sh
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```
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Open the `Flow_Controller_Panel-Front.pm4n` file to visually verify before printing.
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<img src="images/Chitubox_preview.png" alt="Chitubox_preview" width="1000"/>
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*If you want to automate the conversion of gerber to printing files, you can jump to the section [Appendix: Automated script](#appendix-automated-script).*
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### 5. Print
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Place the presensitized copper board on the **Anycubic Photon Mono 4** printer's LCD screen. Copy the file `Flow_Controller_Panel-Front.pm4n` on the USB drive and 3D print it.
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### 6. Developing
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1. After exposure, you must develop the board to reveal the pattern.
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* For a **positive photoresist board** (like the Bungard brand), the developer is a weak alkaline solution. A common and effective developer is a **1% solution of Sodium Hydroxide (NaOH)** in distilled or demineralised water.
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* For the **UV light curing solder mask**, allow more time to it to harden. Clean the uncured part with Izopropanol afterwards.
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2. **Safety First:** When working with chemicals like NaOH, always wear gloves and eye protection.
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3. Submerge the board in the developer solution and gently agitate it. This should take 30-90 seconds, depending on the resist and developer freshness.
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4. Rinse the board thoroughly with water.
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### 7. Etching
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For the developed Bungard photoresist PCB, etch the board using either `sodium persulfate` or `ferric chloride`.
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- For `sodium persulfate`, prepare a solution with approximately 200–250 g/L and heat it to 40–50 °C.
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- For `ferric chloride`, use a ready-to-use solution or prepare it according to the manufacturer's instructions and maintain a temperature of 35–45 °C.
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Immerse the board in the etchant and agitate gently until all exposed copper has been removed, typically within 5–15 minutes. Rinse the board thoroughly with water after etching. To remove the remaining photoresist, immerse the board in a 2–5% `sodium hydroxide (NaOH)` solution at room temperature for 1–2 minutes, then rinse thoroughly with water and dry the board.
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### 8. Drilling holes and milling board outlines
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Use the project [kicad2gcode](https://gitea.virtonline.eu/2HoursProject/kicad2gcode) to generate G-Code for CNC driling and outlines milling.
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---
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## Appendix: Automated script
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Automate the conversion from KiCAD to print files using a CLI.
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### 1. The `Dummy.pm4n` file
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Make sure you have the `Dummy.pm4n` file specific to your printer. See the section [5. Create the `Dummy.pm4n` file](#5-create-the-dummypm4n-file) above.
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### 2. Setup the `UVtools` wrapper
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Make sure `UVtools` is installed - follow the section [1. Install `UVtools`](#1-install-uvtools).
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By default `pcb-expose.sh` looks for `~/UVtools/UVtoolsCmd`. Override with:
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```bash
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export UVTOOLSCMD=~/UVtools/UVtoolsCmd
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```
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### 3. Export KiCAD gerbers
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```bash
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kicad-cli pcb export gerbers \
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-o gerbers \
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-l F.Cu,B.Cu,F.Mask,B.Mask,F.SilkS,B.SilkS \
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../kicad2panel/panel/Flow_Controller_Panel.kicad_pcb
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```
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Output:
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```bash
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Plotted to 'gerbers/Flow_Controller_Panel-Front.gtl'.
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Plotted to 'gerbers/Flow_Controller_Panel-Back.gbl'.
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Plotted to 'gerbers/Flow_Controller_Panel-F_Silkscreen.gto'.
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Plotted to 'gerbers/Flow_Controller_Panel-B_Silkscreen.gbo'.
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Plotted to 'gerbers/Flow_Controller_Panel-F_Mask.gts'.
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Plotted to 'gerbers/Flow_Controller_Panel-B_Mask.gbs'.
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```
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### 4. Exposure
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We need to **invert copper and soldermask** layers: `F.Cu,B.Cu,F.Mask,B.Mask,F.SilkS,B.SilkS`.
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We need to **mirror all front** layers: `F.Cu,F.Mask,F.SilkS`.
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Traces should appear black on white background.
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- background = UV exposed = resist removed = etched away
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- traces = dark = resist kept = copper stays
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Start with `--exposure 60` and bracket from there — **Bungard** presensitized at 405nm typically lands between 30–180s depending on board vintage and storage.
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UV light curing Solder Mask from **Mechanic** needs 15 minutes when prebaked (heat it to 80C for 15 minutes) otherwise 30 minutes. Use green as the solder mask and white for the silkscreen.
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#### 4.1. Export print files for copper layers
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Export the front and back **copper** layers for 120 seconds exposure
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```bash
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pcb-expose.sh Dummy.pm4n gerbers/Flow_Controller_Panel-Front.gtl \
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--invert --mirror --exposure 120 \
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--output pm4n/Flow_Controller_Panel-Front.pm4n
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pcb-expose.sh Dummy.pm4n gerbers/Flow_Controller_Panel-Back.gbl \
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--invert --exposure 120 \
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--output pm4n/Flow_Controller_Panel-Back.pm4n
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```
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#### 4.2. Export print files for soldermask layers
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Export the front and back **soldermask** layers for 900 seconds exposure
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```bash
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pcb-expose.sh Dummy.pm4n gerbers/Flow_Controller_Panel-F_Mask.gts \
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--invert --mirror --exposure 900 \
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--output pm4n/Flow_Controller_Panel-F_Mask.pm4n
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pcb-expose.sh Dummy.pm4n gerbers/Flow_Controller_Panel-B_Mask.gbs \
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--invert --exposure 900 \
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--output pm4n/Flow_Controller_Panel-B_Mask.pm4n
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```
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#### 4.1. Export print files for silkscreen layers
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Export the front and back **silkscreen** layers for 900 seconds exposure
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```bash
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pcb-expose.sh Dummy.pm4n gerbers/Flow_Controller_Panel-F_Silkscreen.gto \
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--mirror --exposure 900 \
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--output pm4n/Flow_Controller_Panel-F_Silkscreen.pm4n
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pcb-expose.sh Dummy.pm4n gerbers/Flow_Controller_Panel-B_Silkscreen.gbo \
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--exposure 900 \
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--output pm4n/Flow_Controller_Panel-B_Silkscreen.pm4n
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```
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### 5. Verify
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Open the `.pm4n` files in **Chitubox Basic** slicer to visually verify before printing. See the section [4. Check the printer exposure](#4-check-the-printer-exposure).
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---
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## Troubleshooting
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**`kicad-cli: command not found`** — add KiCad to PATH:
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```bash
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export PATH="/usr/lib/kicad/bin:$PATH"
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```
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Or on Flatpak:
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```bash
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alias kicad-cli='flatpak run --command=kicad-cli org.kicad.KiCad'
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```
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**Expected Gerber not found** — KiCad's layer→filename mapping:
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| Layer | Filename stem |
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|---|---|
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| `F.Cu` | `Front` |
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| `B.Cu` | `Back` |
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| `F.Mask` | `F_Mask` |
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| `B.Mask` | `B_Mask` |
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| `F.SilkS` | `F_Silkscreen` |
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---
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