UNIVERSITY SCHOOL OF AUTOMATION AND

ROBOTICS
GURU GOBIND SINGH INDRAPRASTHA UNIVERSITY
EAST DELHI CAMPUS, SURAJMAL VIHAR, DELHI-110032

Summer Training Report

on

PCB designing and Additive Manufacturing

Submitted in partial fulfillment of the requirements for the completion of one

month’s summer internship/training [ART 355]

Name: Shiv Sagar Kumar Sinha

Enrollment Number: 01019012022

Under the supervision of

Mr. K Kiran Kumar

Mr. Dipesh Verma
Project Engineer
CDAC, Noida

[1]
 CERTIFICATE OF COMPLETION

DECLARATION

I hereby declare that the Summer Training Report entitled (PCB designing and fabrication)
is an authentic record of work completed as requirements of Summer Training (ART 355)
during the period from
01/07/2024 to 31/07/2024 in Centre for Development of Advanced Computing under the
supervision of Mr. K Kiran Kumar and Mr. Dipesh Verma.

[2]
 Shiv Sagar Kumar Sinha
01719012022
Date:

Dr Amanpreet Singh

Date:

[3]
 ACKNOWLEDGEMENT

I am deeply appreciative of the expertise and guidance provided by Centre for Development of
Advanced Computing during the PCB designing phase. Their technical insights and collaborative
approach significantly contributed to the efficient layout and functionality of the printed circuit board.

Furthermore, Centre for Development of Advanced Computing demonstrated exceptional problem-

solving skills, addressing any challenges that arose during the design phase promptly and effectively.
Their proactive approach in anticipating potential issues and proposing innovative solutions underscored
their dedication to delivering a high-quality PCB design.

[4]
The Centre at Noida formerly known as ER&DCI, Noida - is a constituent unit of C-DAC,
working from two campuses (R&D and Academic) separated by a distance of about 100
meters. Since its inception in 1994, the R & D Wing of the centre has been working in
application oriented design and development for various customer requirements. It has acquired
competency, expertise and extensive experience in the areas of Strategic Electronics &
Embedded Systems, Cyber Security, Health Informatics, e-Governance and Multilingual
Computing.

The Education and Training Wing focuses on generation of quality manpower both in formal
education as well as advanced computing areas. As part of its formal education initiative C-
DAC offers MCA, M.Tech (CSE, IT and VLSI) and MBA courses, recognized by AICTE and
duly affiliated to Guru Gobind Singh Indraprastha University, New Delhi. The center provides
training in niche areas of ICT. Post- Graduate Diploma courses are also offered in various
specializations like Artificial Intelligence, Big Data, Advanced Software Development,
Embedded Systems etc.

The Academic Wing is spread across approximately 5 Acres - hostel measuring around 40,000
sq.ft and Academic Block measuring about 100000 sq.ft. (fully air-conditioned).

The centre also has a Tier – III Design Certified Data Centre which is currently being upgraded
to achieve an uptime Tier- III Certification facility with concurrent maintainability standards.
The capacity of the Data centre has been designed with peak load calculations considering the
micro components to ensure that no failure occurs due to over load. Availability and security
are of primary importance as the Data centre is hosting critical mission mode applications.

C-DAC Noida accords prime importance to reliability and maintainability of its systems
deployed in field. The technology development initiatives of the Centre are highly focused in
the above areas and are obtained predominantly with funding from various Ministries and
Departments of Government of India, State Governments and other agencies.

The current employee strength of the Centre is around 400 with about 70% technical
manpower.

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 TABLE OF CONTENT

S.NO. TITLE PAGE NO.

1 Abstract 7

2 Introduction 8

3 Software and hardware used 9-10

Course work 11-27
4
28-31
5 Assessment

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 ABSTRACT

Printed Circuit Boards (PCBs) serve as the backbone of modern electronic systems, providing a
platform for interconnecting various components to facilitate seamless functionality. This
abstract outlines an integrated approach to PCB designing and fabrication, focusing on
optimizing performance, reliability, and efficiency in electronic systems.

The PCB design phase involves meticulous planning, component placement, and routing to
ensure signal integrity, minimize electromagnetic interference, and enhance thermal
management. Advanced design tools and simulation techniques are employed to analyze and
optimize the layout, considering factors such as impedance matching, power distribution, and
high-speed signal integrity.

The fabrication process is a critical step in translating the design into a physical PCB. Utilizing
state-of-the-art manufacturing techniques, including precision drilling, multi-layer lamination,
and controlled impedance processing, ensures the creation of high-quality PCBs. The selection
of appropriate materials, surface finishes, and soldering technologies further contributes to the
reliability and longevity of the electronic system.

INTRODUCTION
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Our journey of first 15 days in PCB fabrication began with a focus on Signal processing and
VLSI. where we explored networks such as WiFi, Bluetooth, and Zigbee, along with various
radio frequencies like AM, FM, and CDMA 450. We then delved into circuits enabling
clocking signals, such as the Multi Vibrator Circuit and Quartz Oscillator. Moving on to analog
electronics basics, we covered Diode Circuits, Transistor Biasing, Low frequencies, transistor
Frequency responses, general feedback Amplifiers, and Power Amplifiers.

Our coursework emphasized Modulation circuits and their Integrated Circuits (ICs), with a
special focus on the NE555 timer IC. We extensively studied its responses in various circuits,
tuning outputs according to timer pulses. We learned about the footprints of multiple ICs
available in the market, understanding their specifications, build types, sizes, and
manufacturing companies. In our lab work, we explored mounting types like SMD and
Through Hole.

Transitioning to basic Digital Electronics, we covered gates, TTL logic values, and Boolean
algebra while preparing circuits for specific problem statements. Our studies extended to
various wired connectors and wireless connectivity topologies, with the DB9 connector being
highlighted for its suitability in robotic and electronic power grid circuits. To complete our
digital-to-analog signal line, we employed the MAX-232 converter.

On remaining 15 days we explored about additive manufacturing and solid works, we derived
into the fascinating world of additive manufacturing. Additive manufacturing, commonly
known as 3D printing, is a process of creating three-dimensional objects by adding material
layer by layer, guided by digital models.

We explored various types of additive manufacturing, including:

1. Fused Deposition Modelling (FDM): Utilizes thermoplastic filaments, which are

heated and extruded layer by layer to build the object.
2. Stereo lithography (SLA): Uses a laser to cure liquid resin into solid plastic, creating
high-resolution parts.
3. Selective Laser Sintering (SLS): Employs a laser to sinter powdered material, usually
nylon, fusing it layer by layer to form durable parts.
4. Direct Metal Laser Sintering (DMLS): Similar to SLS but uses metal powders,
allowing for the creation of complex metal components.

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 SOFTWARE USED

During our one-month course at CDAC, we had the valuable opportunity to utilize Autodesk
EAGLE for the purpose of designing printed circuit boards (PCBs). This experience
significantly enhanced our skills in schematic capture, PCB layout, and the generation of
manufacturing files. Notably, EAGLE served as an instrumental tool not only for ensuring the
functionality of our designs but also for elevating the aesthetic appeal of the PCBs. Through
strategic component placement, thoughtful routing of traces, and the utilization of features such
as silk screen layers and custom graphics, we were able to create visually pleasing and
professionally crafted PCB layouts. This hands-on experience in both the technical and
aesthetic aspects of PCB design has equipped us with a comprehensive skill set that is
invaluable in the field of electronics.

SolidWorks is a premier 3D CAD software extensively utilized in the realm of additive

manufacturing. This software empowers engineers and designers to craft detailed and precise
models, which are essential for the additive manufacturing process. Additive manufacturing,
also known as 3D printing, involves creating objects layer by layer from digital models.
SolidWorks plays a critical role in this process by providing robust tools for designing,
simulating, and optimizing parts, ensuring they are ready for efficient and accurate 3D printing.

One of the standout features of SolidWorks in the context of additive manufacturing is its
ability to handle complex geometries and intricate designs. This capability is particularly
important because additive manufacturing allows for the creation of shapes and structures that
are difficult or impossible to achieve with traditional manufacturing methods. SolidWorks
enables designers to take full advantage of this flexibility, pushing the boundaries of what can
be manufactured.

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 HARDWARE USED

The specific hardware used for PCB fabricating at CDAC (Centre for Development of
Advanced Computing) may vary based on the facility's capabilities and technological
advancements, a typical setup includes specialized equipment tailored for the manufacturing
and production of printed circuit boards. CDAC likely employs precision machinery such as
PCB milling machines for the precise removal of copper from substrates during prototyping.
These facilities may also feature automated tools for drilling, cutting, and soldering
components onto the fabricated boards. Accurate measurement tools, such as calipers and
micrometers, are likely used to ensure the precise dimensions of the fabricated PCBs. To
support these processes, CDAC would have reliable power supplies, ensuring stability during
testing and prototyping phases. The combination of advanced manufacturing equipment and
precise measurement tools at CDAC contributes to an efficient and quality-driven PCB
fabrication process.

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 COURSE WORK
During our course period at CDAC (Centre for Development of Advanced Computing), we
delved into the intricate world of printed circuit board (PCB) design using Eagle, a popular
PCB design software. This experience was both challenging and rewarding as we navigated
through the various aspects of the design process, from schematic capture to layout and routing.

1. 4X4 keypad Circuit

Figure 1 circuit diagram

Typically one port pin is required to read a digital input into the controller. When there are a lot
of digital inputs that have to be read, it is not feasible to allocate one pin for each of them. This
is when a matrix keypad arrangement is used to reduce the pin count.

Therefore, the number of pins that are required to interface a given number of inputs decreases
with increase in the order of the matrix.
Interface Logic: Initially all switches are assumed to be released. So there is no connection
between the rows and columns. When any one of the switches are pressed, the corresponding
row and column are connected (short circuited). This will drive that column pin (initially high)
low. Using this logic, the button press can be detected. The colors red and black is for logic
high and low respectively. Here are the steps involved in determining the key that was pressed.

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4X4 KEYPAD with Controller schematic

4X4 KEYPAD with Controller Layout

[12]
4X4 KEYPAD with Controller manufacturing file

2. Basic LED CIRCUIT

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 A basic LED circuit is an elementary electronic configuration designed to light up a Light
Emitting Diode (LED). The core components of this circuit include an LED, a resistor, a
power source (like a battery or DC power supply), and connecting wires. The LED, which has
two legs, the anode (positive) and the cathode (negative), is the main element that emits light
when current passes through it. The resistor plays a crucial role in this circuit by limiting the
current flowing through the LED, thereby preventing it from burning out. To build the circuit,
the anode of the LED is connected to one end of the resistor, while the other end of the
resistor is connected to the positive terminal of the power source. The cathode of the LED is
then connected to the negative terminal of the power source. When the circuit is complete and
power is supplied, current flows from the positive terminal through the resistor, then through
the LED, causing it to light up, and finally returns to the negative terminal of the power
source.

Figure 2 circuit diagram

[14]
Schematic

manufacturing file

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 3. NE555 Circuit
Creating an LED emergency lamp using the NE555 timer IC is a simple and effective project.
The NE555 is a versatile IC commonly used for generating pulses, oscillations, and timing
applications. In this case, it can be configured as an astable multivibrator to generate a blinking
effect for the LEDs.
No microcontroller code is needed for this circuit since the NE555 timer IC is an analog device.
Adjust the values of resistors and capacitors as needed to achieve the desired blinking
frequency. The NE555, configured as an astable multivibrator, generates a square wave output
on pin 3 (OUT). This output drives the transistor, which, in turn, controls the LEDs. The
blinking effect is created by the charging and discharging of the capacitor C1.
Remember to be cautious with the current requirements of your LEDs and select appropriate
resistors to limit the current. Additionally, check the datasheets for the NE555 and other
components for detailed specifications.
Its applications in generating precise time delays, oscillations, and pulse-width modulation.
Operating in astable and monostable modes, it has found use in various electronic circuits, from
LED flashers and pulse generators to PWM controllers. While popular for educational
purposes, it may lack the precision of modern microcontrollers.

Figure 4 circuit diagram

[16]
schematic

layout

[17]
manufacturing file

4. MAX232 Driver Circuit

The MAX232 is a popular IC used for converting RS-232 voltage levels to TTL/CMOS levels,
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and vice versa. It's commonly employed in serial communication applications to interface
microcontrollers, microprocessors, or other digital devices with RS-232 serial ports on
computers or other peripherals.
The MAX232 operates on a dual power supply, typically +5V for Vcc and -5V for Vee.
However, many modern versions of the MAX232 have internal charge pumps that generate the
necessary negative voltage, allowing you to power the IC with a single +5V supply.
Double-check the pinout and specifications in the MAX232 datasheet, as different versions and
manufacturers may have variations.
Ensure that the communication parameters (baud rate, data bits, stop bits, parity) of your
microcontroller and the RS-232 device match to establish reliable serial communication.
This basic circuit allows you to interface a microcontroller with RS-232 devices using the
MAX232, converting TTL/CMOS voltage levels to RS-232 levels and vice versa. Always refer
to the datasheet of the specific MAX232 version you are using for detailed information and
specifications.

Figure 5 circuit diagram

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MAX232 driver with Mega16P schematic

MAX232 driver with Mega16P layout

[20]
MAX232 driver with Mega16P manufacturing file

5. PUSH Button with 4 LED Circuit

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a simple push-button LED circuit using an ATmega32 microcontroller, you'll need a few
components including an ATmega32 microcontroller, an LED, a current-limiting resistor, and a
push-button switch. Here's a basic circuit
ATmega32 microcontroller embodies a foundational exploration of embedded systems. This
educational prototype introduces users to the integration of hardware and software,
emphasizing key principles such as GPIO interfacing, real-time response, and energy
efficiency.
The integration of a push-button emphasizes the importance of human-centric design in
technology. The tactile feedback of a physical button adds an element of user experience,
highlighting the significance of considering user interactions in electronic systems.
The circuit serves as a foundational component in the development of smart devices. As part of
a larger system, it exemplifies how a simple user interface element can trigger complex
functionalities in devices ranging from smart home appliances to wearable gadgets.

Figure 62 circuit diagram

[22]
Led and Pushbutton to mega32P schematic

Led and Pushbutton to mega32P layout

[23]
Led and Pushbutton to mega32P manufacturing file

6. 8 PUSH Button with 8 LED Circuit

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Constructing a straightforward LED circuit with a push-button using the ATmega32
microcontroller requires several components: an ATmega32 microcontroller itself, an LED, a
current-limiting resistor, and a push-button switch. This basic circuit serves as an introductory
exploration into embedded systems. It serves as an educational prototype, acquainting users
with the fusion of hardware and software and emphasizing fundamental principles like GPIO
interfacing, real-time responsiveness, and energy efficiency.

The ATmega32 microcontroller's versatility extends its utility to diverse applications, spanning
the domains of the Internet of Things (IoT), industrial control, and smart devices. Its
adaptability positions it as a fundamental building block for a range of projects. Functioning as
a rapid prototyping tool, the circuit expedites development cycles, providing valuable insights
into digital control mechanisms and user-centric design considerations.

Figure 7 circuit diagram

[25]
Led and Pushbutton to mega32P schematic

Led and Pushbutton to mega32P layout

[26]
Led and Pushbutton to mega32P manufacturing file

[27]
PROBLEM STATEMENT
1. Design the schematic and layout for "TOY Music Player"
Design files: 1) Schematic PDF; 2) Layout PDF & 3) Gerber files.

A toy music player is a child-friendly device designed to play pre-recorded music or sounds. It
typically features simple controls like buttons for play, pause, and volume adjustment, along
with a speaker to output sound.

Figure 8 circuit diagram

[28]
schematic

[29]
manufacturing file

[30]
 Additive manufacturing Assessment

Snowman toy

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