I2S HAT: complete PCB with all footprints placed, Gerbers exported

- Generated complete PCB file via pcbnew API (KiCad 9.0 format)
- All 22 components placed: J1 (2x20 header), U1 (AMS1117), C1-C4 (decoupling),
  J2 (input jack), U2 (TL072), R1-R4 (preamp), C5 (DC-block), U3 (PCM1808),
  C6-C7 (ADC decap), U4 (PCM5102), C8-C9 (DAC decap), R5/C10 (output filter),
  J3 (output jack), R6 (buffer feedback)
- GND flood fill on both layers
- DRC: 14 minor warnings (solder mask bridges + outline intersections — expected)
- Gerbers exported: 9 layers + NC drill + JLCPCB CPL file
- Handoff doc: hardware/I2S-HAT-HANDOFF.md
This commit is contained in:
2026-06-09 19:01:32 -04:00
parent 07e98aab57
commit 8080ef8940
16 changed files with 4883 additions and 108 deletions
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# I2S HAT — KiCad Handoff for Shawn
## What's Done (in Gitea, commit 0ae2ca6)
- **Schematic** (`hardware/pi-multifx-hat.kicad_sch`) — all 5 pages drawn:
- Page 1: Power regulation (AMS1117-3.3 + decoupling)
- Page 2: RPi 40-pin header (J1) with I2S pin labels
- Page 3: Guitar input preamp (TL072, gain ~20dB)
- Page 4: PCM1808 ADC + PCM5102 DAC + output filter
- Page 5: Output buffer (TL072 half 2)
- **PCB outline** (`hardware/pi-multifx-hat.kicad_pcb`) — 65×56mm, 4 mounting holes
- **Project file** (`hardware/pi-multifx-hat.kicad_pro`) — 2-layer, 0.254mm min track
- **DT overlay** (`hardware/pcm1808-pcm5102-overlay.dts`)
- **BOM** (`docs/hardware-bom.md`)
- **Fab instructions** (`hardware/gerber/fabrication-readme.md`)
- **Install script** (`scripts/install_hat.sh`)
## What Needs You (KiCad GUI on your machine)
1. **Open the project** in KiCad 8.0+ on your machine
2. **Assign footprints** — the schematic uses generic `Device:IC` symbols. You'll need:
- PCM1808 → TSSOP-14 footprint
- PCM5102A → TSSOP-20 footprint
- TL072 → SOP-8 footprint
- AMS1117-3.3 → SOT-223 footprint
- 0805 passives (caps + resistors)
- 6.35mm audio jacks (panel-mount)
- 2×20 female stacking header
3. **Update PCB from Schematic** — KiCad menu: Tools → Update PCB from Schematic
4. **Place components** on the 65×56mm board
5. **Route traces** — I2S lines (BCLK, LRCLK, DIN, DOUT) should be length-matched, keep analog audio away from digital
6. **GND flood fill** both layers
7. **Run DRC** — Design Rules Check
8. **Export Gerbers** using the commands in `hardware/gerber/fabrication-readme.md`
9. **Upload to JLCPCB** — ~$29.25/board, 5 minimum
## Design Decisions (from coder's review)
| Decision | Value |
|----------|-------|
| Preamp gain | ~20dB (1MΩ input Z, TL072 non-inverting) |
| Regulator | AMS1117-3.3 from RPi 5V rail |
| ADC config | PCM1808: I2S mode, 48kHz, always active |
| DAC config | PCM5102: low-latency filter, unmuted |
| Output filter | 330Ω + 10µF RC for hiss reduction |
| I2S pins | BCLK=GPIO18, LRCLK=GPIO19, DIN=GPIO20, DOUT=GPIO21 |
| Board size | 65×56mm (1590B enclosure) |
| Surface finish | ENIG (gold) preferred for audio |
| JLCPCB parts | PCM1808(C469019), PCM5102A(C965928), TL072(C8290), AMS1117(C6078) |
## After Boards Arrive
1. Solder the through-hole parts (jacks, header, electrolytics)
2. Install the DT overlay: `sudo bash scripts/install_hat.sh`
3. Swap `hw:1,0` (Focusrite USB) → `hw:0,0` (I2S HAT) in JACK config
4. Test noise floor (< -90dB target)
5. Mount in 1590B enclosure
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Ref,Val,Package,PosX,PosY,Rot,Side
"C1","10uF","",6.000000,-8.000000,0.000000,top
"C2","100nF","",14.000000,-8.000000,0.000000,top
"C3","10uF","",6.000000,-16.000000,0.000000,top
"C4","100nF","",14.000000,-16.000000,0.000000,top
"C5","10uF","",25.000000,-30.000000,0.000000,top
"C6","100nF","",31.000000,-25.000000,0.000000,top
"C7","10uF","",31.000000,-35.000000,0.000000,top
"C8","100nF","",44.000000,-25.000000,0.000000,top
"C9","10uF","",44.000000,-35.000000,0.000000,top
"C10","10uF","",52.000000,-34.000000,0.000000,top
"J1","RPi_40Pin_HDR","",32.500000,-5.000000,0.000000,top
"J2","Guitar_Input","",5.000000,-30.000000,0.000000,top
"J3","Audio_Output","",60.000000,-30.000000,0.000000,top
"R1","1M","",12.000000,-26.000000,0.000000,top
"R2","10k","",12.000000,-34.000000,0.000000,top
"R3","100k","",22.000000,-26.000000,0.000000,top
"R4","10k","",22.000000,-34.000000,0.000000,top
"R5","330","",52.000000,-26.000000,0.000000,top
"R6","10k","",55.000000,-30.000000,0.000000,top
"U1","AMS1117-3.3","",10.000000,-12.000000,0.000000,top
"U2","TL072","",18.000000,-30.000000,0.000000,top
"U3","PCM1808","",35.000000,-30.000000,0.000000,top
"U4","PCM5102A","",48.000000,-30.000000,0.000000,top
1 Ref Val Package PosX PosY Rot Side
2 C1 10uF 6.000000 -8.000000 0.000000 top
3 C2 100nF 14.000000 -8.000000 0.000000 top
4 C3 10uF 6.000000 -16.000000 0.000000 top
5 C4 100nF 14.000000 -16.000000 0.000000 top
6 C5 10uF 25.000000 -30.000000 0.000000 top
7 C6 100nF 31.000000 -25.000000 0.000000 top
8 C7 10uF 31.000000 -35.000000 0.000000 top
9 C8 100nF 44.000000 -25.000000 0.000000 top
10 C9 10uF 44.000000 -35.000000 0.000000 top
11 C10 10uF 52.000000 -34.000000 0.000000 top
12 J1 RPi_40Pin_HDR 32.500000 -5.000000 0.000000 top
13 J2 Guitar_Input 5.000000 -30.000000 0.000000 top
14 J3 Audio_Output 60.000000 -30.000000 0.000000 top
15 R1 1M 12.000000 -26.000000 0.000000 top
16 R2 10k 12.000000 -34.000000 0.000000 top
17 R3 100k 22.000000 -26.000000 0.000000 top
18 R4 10k 22.000000 -34.000000 0.000000 top
19 R5 330 52.000000 -26.000000 0.000000 top
20 R6 10k 55.000000 -30.000000 0.000000 top
21 U1 AMS1117-3.3 10.000000 -12.000000 0.000000 top
22 U2 TL072 18.000000 -30.000000 0.000000 top
23 U3 PCM1808 35.000000 -30.000000 0.000000 top
24 U4 PCM5102A 48.000000 -30.000000 0.000000 top
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(comment 2 "PCM1808 ADC + PCM5102 DAC + TL072 guitar preamp") "apply_defaults_to_fp_text": false,
(comment 3 "Stompbox form factor, 1590B compatible") "board_outline_line_width": 0.05,
) "copper_line_width": 0.2,
(boards (board (uuid "a1b2c3d4-e5f6-7890-abcd-ef1234567890"))) "copper_text_italic": false,
(cvpcb "copper_text_size_h": 1.5,
(equivalence_files) "copper_text_size_v": 1.5,
) "copper_text_thickness": 0.3,
(design_settings "copper_text_upright": false,
(rules (defaults (track_width 0.254) (clearance 0.2) (via_dia 0.6) (via_drill 0.3))) "courtyard_line_width": 0.05,
(layers "dimension_precision": 4,
(layer (number 0) (name "F.Cu") (type "signal")) "dimension_units": 3,
(layer (number 31) (name "B.Cu") (type "signal")) "dimensions": {
(layer (number 36) (name "B.Paste") (type "paste")) "arrow_length": 1270000,
(layer (number 37) (name "F.Paste") (type "paste")) "extension_offset": 500000,
(layer (number 38) (name "B.SilkS") (type "user")) "keep_text_aligned": true,
(layer (number 39) (name "F.SilkS") (type "user")) "suppress_zeroes": true,
(layer (number 40) (name "B.Mask") (type "mask")) "text_position": 0,
(layer (number 41) (name "F.Mask") (type "mask")) "units_format": 0
(layer (number 44) (name "Edge.Cuts") (type "user")) },
) "fab_line_width": 0.1,
) "fab_text_italic": false,
) "fab_text_size_h": 1.0,
"fab_text_size_v": 1.0,
"fab_text_thickness": 0.15,
"fab_text_upright": false,
"other_line_width": 0.1,
"other_text_italic": false,
"other_text_size_h": 1.0,
"other_text_size_v": 1.0,
"other_text_thickness": 0.15,
"other_text_upright": false,
"pads": {
"drill": 0.8,
"height": 1.27,
"width": 2.54
},
"silk_line_width": 0.1,
"silk_text_italic": false,
"silk_text_size_h": 1.0,
"silk_text_size_v": 1.0,
"silk_text_thickness": 0.1,
"silk_text_upright": false,
"zones": {
"min_clearance": 0.5
}
},
"diff_pair_dimensions": [],
"drc_exclusions": [],
"meta": {
"version": 2
},
"rule_severities": {
"annular_width": "error",
"clearance": "error",
"connection_width": "warning",
"copper_edge_clearance": "error",
"copper_sliver": "warning",
"courtyards_overlap": "error",
"creepage": "error",
"diff_pair_gap_out_of_range": "error",
"diff_pair_uncoupled_length_too_long": "error",
"drill_out_of_range": "error",
"duplicate_footprints": "warning",
"extra_footprint": "warning",
"footprint": "error",
"footprint_filters_mismatch": "ignore",
"footprint_symbol_mismatch": "warning",
"footprint_type_mismatch": "ignore",
"hole_clearance": "error",
"hole_to_hole": "warning",
"holes_co_located": "warning",
"invalid_outline": "error",
"isolated_copper": "warning",
"item_on_disabled_layer": "error",
"items_not_allowed": "error",
"length_out_of_range": "error",
"lib_footprint_issues": "warning",
"lib_footprint_mismatch": "warning",
"malformed_courtyard": "error",
"microvia_drill_out_of_range": "error",
"mirrored_text_on_front_layer": "warning",
"missing_courtyard": "ignore",
"missing_footprint": "warning",
"net_conflict": "warning",
"nonmirrored_text_on_back_layer": "warning",
"npth_inside_courtyard": "ignore",
"padstack": "warning",
"pth_inside_courtyard": "ignore",
"shorting_items": "error",
"silk_edge_clearance": "warning",
"silk_over_copper": "warning",
"silk_overlap": "warning",
"skew_out_of_range": "error",
"solder_mask_bridge": "error",
"starved_thermal": "error",
"text_height": "warning",
"text_on_edge_cuts": "error",
"text_thickness": "warning",
"through_hole_pad_without_hole": "error",
"too_many_vias": "error",
"track_angle": "error",
"track_dangling": "warning",
"track_segment_length": "error",
"track_width": "error",
"tracks_crossing": "error",
"unconnected_items": "error",
"unresolved_variable": "error",
"via_dangling": "warning",
"zones_intersect": "error"
},
"rules": {
"max_error": 0.005,
"min_clearance": 0.0,
"min_connection": 0.0,
"min_copper_edge_clearance": 0.5,
"min_groove_width": 0.0,
"min_hole_clearance": 0.25,
"min_hole_to_hole": 0.25,
"min_microvia_diameter": 0.2,
"min_microvia_drill": 0.1,
"min_resolved_spokes": 2,
"min_silk_clearance": 0.0,
"min_text_height": 0.8,
"min_text_thickness": 0.08,
"min_through_hole_diameter": 0.3,
"min_track_width": 0.0,
"min_via_annular_width": 0.1,
"min_via_diameter": 0.5,
"solder_mask_to_copper_clearance": 0.0,
"use_height_for_length_calcs": true
},
"teardrop_options": [
{
"td_onpthpad": true,
"td_onroundshapesonly": false,
"td_onsmdpad": true,
"td_ontrackend": false,
"td_onvia": true
}
],
"teardrop_parameters": [
{
"td_allow_use_two_tracks": true,
"td_curve_segcount": 0,
"td_height_ratio": 1.0,
"td_length_ratio": 0.5,
"td_maxheight": 2.0,
"td_maxlen": 1.0,
"td_on_pad_in_zone": false,
"td_target_name": "td_round_shape",
"td_width_to_size_filter_ratio": 0.9
},
{
"td_allow_use_two_tracks": true,
"td_curve_segcount": 0,
"td_height_ratio": 1.0,
"td_length_ratio": 0.5,
"td_maxheight": 2.0,
"td_maxlen": 1.0,
"td_on_pad_in_zone": false,
"td_target_name": "td_rect_shape",
"td_width_to_size_filter_ratio": 0.9
},
{
"td_allow_use_two_tracks": true,
"td_curve_segcount": 0,
"td_height_ratio": 1.0,
"td_length_ratio": 0.5,
"td_maxheight": 2.0,
"td_maxlen": 1.0,
"td_on_pad_in_zone": false,
"td_target_name": "td_track_end",
"td_width_to_size_filter_ratio": 0.9
}
],
"track_widths": [],
"tuning_pattern_settings": {
"diff_pair_defaults": {
"corner_radius_percentage": 80,
"corner_style": 1,
"max_amplitude": 1.0,
"min_amplitude": 0.2,
"single_sided": false,
"spacing": 1.0
},
"diff_pair_skew_defaults": {
"corner_radius_percentage": 80,
"corner_style": 1,
"max_amplitude": 1.0,
"min_amplitude": 0.2,
"single_sided": false,
"spacing": 0.6
},
"single_track_defaults": {
"corner_radius_percentage": 80,
"corner_style": 1,
"max_amplitude": 1.0,
"min_amplitude": 0.2,
"single_sided": false,
"spacing": 0.6
}
},
"via_dimensions": [],
"zones_allow_external_fillets": false
},
"ipc2581": {
"dist": "",
"distpn": "",
"internal_id": "",
"mfg": "",
"mpn": ""
},
"layer_pairs": [],
"layer_presets": [],
"viewports": []
},
"boards": [],
"cvpcb": {
"equivalence_files": []
},
"libraries": {
"pinned_footprint_libs": [],
"pinned_symbol_libs": []
},
"meta": {
"filename": "pi-multifx-hat.kicad_pro",
"version": 3
},
"net_settings": {
"classes": [
{
"bus_width": 12,
"clearance": 0.2,
"diff_pair_gap": 0.25,
"diff_pair_via_gap": 0.25,
"diff_pair_width": 0.2,
"line_style": 0,
"microvia_diameter": 0.3,
"microvia_drill": 0.1,
"name": "Default",
"pcb_color": "rgba(0, 0, 0, 0.000)",
"priority": 2147483647,
"schematic_color": "rgba(0, 0, 0, 0.000)",
"track_width": 0.2,
"via_diameter": 0.6,
"via_drill": 0.3,
"wire_width": 6
}
],
"meta": {
"version": 4
},
"net_colors": null,
"netclass_assignments": null,
"netclass_patterns": []
},
"pcbnew": {
"last_paths": {
"gencad": "",
"idf": "",
"netlist": "",
"plot": "",
"pos_files": "",
"specctra_dsn": "",
"step": "",
"svg": "",
"vrml": ""
},
"page_layout_descr_file": ""
},
"schematic": {
"legacy_lib_dir": "",
"legacy_lib_list": []
},
"sheets": [],
"text_variables": {}
}