My processes and suppliers

I design printed circuit boards using KiCad computer aided design (CAD) open source software.

OSHPark makes inexpensive PCBs. OSH means open source hardware

OSHStencils makes stencils to silkscreen solder paste onto the boards.

Digikey distributes electronic components. Mouser and Jameco also do.

I get small quantities of surplus or salvaged motors from eBay and Alibaba. Small motors are expensive or hard to find, especially new or brushless motors. The manufacturers want to sell a minimum of a thousand. But there is a huge surplus of “pager” motors used to vibrate cell phones.

I place surface mount devices (SMD) components onto a PCB using a hypodermic needle with a tube to my mouth. Some people use tweezers or a hand held, vacuum tool.

I can only handle discretes no smaller than Imperial 0603 size. I use IC packages QFN and XSON-4 which TI calls DQN (for four lead mosfets) having pitch (between pins) of no less than 0.5mm. I often use custom footprints where the pads stick out beyond the package enough that I can swipe a solder iron along the package to touch up solder joints (so-called hand-solderable footprints.)

I reflow boards in a toaster oven.

The rest of the assembly process is by hand, often using jeweler’s tools and a magnifying glass.

For chimes, I often buy a wind chime and reuse the ringing parts.