OpenSynth Kit Preparation

Today I put together the first 17 OpenSynth Kits.  This took a LONG time, part of which was figuring out how to do things.  For the next batch I’m going to be recruiting some help, there are lots of tasks that can be done in parallel…

First task is to lay out all the parts.

OpenSynth parts as they come from the various suppliers

Next I started by organizing all the passive, non-ESD sensitive parts such as capacitors and resistors.  These are placed onto a piece of card stock with double sided tape, and then covered with self-laminating sheet material.

Passive Non-ESD sensitive parts

Close-up of one of the Passives cards

Next up was the mechanical parts – connectors, wire, and the heat sink.  The wires were cut to length, heat sink adhesive cut and applied (it comes in a large double-sticky sheet) to the heat sinks.  Parts were then placed into ESD bags, sealed and tagged.

Wire, connectors, heat sinks

The next step was to program the microcontrollers and put all the ESD sensitive parts into small plastic foam-lined ESD safe boxes.

ESD parts and microcontroller programming

Finally it is time to seal up the bags!  Some of the parts (the LEDs and microcontrollers are humidity sensitive, so this step included adding dessicant packs and humidity indicator cards to the special humidity resistant bags before themal sealing.

Final kit assembly

Well that is about it!  After this, both the passive component card and ESD parts bags will be put into padded mailing envelopes and headed out the door!

3 thoughts on “OpenSynth Kit Preparation

  1. Tony,
    I just finished building the 2556 MHz synthesizer (unit #1) and other than a couple of part identifier “arrows” missing in the manual, which were easily identified in the schematic, assembly was a breeze. The total construction time was about two hours without the need to stop and test things along the way. After construction, I immediately put power on the unit and connected the 10 MHz reference and the green LED lit up and the frequency counter read 2.556000000 GHz. The output power was measured at +7 dBm and the spectrum was extremely clean.

    So then I constructed the 2556 MHz synthesizer unit number 2 with exactly the same results. They both work great and will be put into service immediately!

    This is the way microwave kits should be.

    Thanks again,

    Dave Glawson – WA6CGR

  2. I see that you made available the docs and PCB files. I tried opening them in Eagle and DipTrace and neither like them. What program did you use to design these? Thanks

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