Velo hybrid - production files for velo hybrid version 1

Version 1
Construction -  4 thou (100um) minimum track and gap 20thou (0.5mm)  lands 8Thou (200um) holes through all layers.
Four copper layers         Start material   5um  double sided copper on  50 um kapton substrate - inner insulator 100um kapton
                                  Final copper thickness on all layers after plating will be 15um

                                  silk screen graphics for component ID
                                  solder mask       60um photo coverlay
                                  M1 - traces, bond pads, SMD component pads     15 um copper 3um nickel w gold flash
                                           50um kapton
                                  M2 - traces    15um copper   estimate
                                           100um kapton
                                  M3 - ground plane 15um copper estimate 
                                           50um kapton
                                  M4 - power plane - not complete over whole board.
                                  complete isolating layer     60um photo coverlay

discrete component attach is by soldering

circuit will be bonded to carbon fibre substrate using epoxy after component attachment

NEW      Copper coverage estimates for radiation length calculation
There is negligible copper inside a radius of 6cm (fingers to connect bias only)
From 6cm to 8cm the coverage is approximately  M1 10%   M2 10%   M3 100%  M4 95%
from 8cm to 10cm the coverage is approximately M1 30%  M2 5%   M3 100% M4 10%
Note that the hybrid is rectangular 17.5* 12.1 cm and the ground plane extends over the whole area
except within the 6cm radius from the centre of the beam. These estimates are made as the proportion of metal
coverage in the part of the annuli within the rectangular outline of the hybrid..

Production files ( gerber RS274x)
silk screen top side
solder resist top side
top side metal,
metal 2.
metal 3 ground plane,
metal 4 power plane
 drill locations

Drill file in excellon format  Drill file        drill report

 mechanical drawing of carbon fibre substrate
 mechanical drawing of kapton circuit
 

More info : design overview
Postscript views of hybrid layers  silkscreen top side   solder resist top sidetop metal 1  metal 2metal 3 ground plane  metal 4 power plane
 

preliminary schematic of hybrid    Connector pinouts  pinout1   pinout2
preliminary cable and connector arrangement drawings  arrangement1arrangement2