# AshLight — draft orders (nothing placed)

Prepared 30 October 2026 for **10 working prototypes** (build 12 of everything, keep 2 as spares
or engineering units). Prices are planning estimates from JLCPCB's live catalogue and published
pricing, not quotes. **No order has been placed, and no supplier has been contacted.**

| # | Vendor | What | Qty | Est. cost (USD) | Blocked on |
|---|---|---|---|---|---|
| A | Adafruit, Raspberry Pi reseller | Stage A0 breadboard kit (see `rev-a0-breadboard.md`) | 1 kit | 60–90 | nothing, ready |
| B | JLCPCB | Main board PCB + PCBA, both sides | 12 | 190–270 | routing (placement done) |
| C | JLCPCB | LED flex PCB + PCBA (consigned LEDs) | 12 | 140–220 | ready: `hardware/pcb/out/ashlight-led-flex-gerbers.zip`, `led_jlc.csv`, `led_jlc_cpl.csv` |
| D | Digi-Key or Mouser | Lumileds L128-RNG1003500000 LEDs, shipped to JLC | 320 | 75–100 | nothing, ready |
| E | Cell supplier | 21700 cells with welded solder tabs | 12 | 80–110 | nothing, ready |
| F | Print (own printer or farm) | Enclosure sets, 8 parts each | 12 | 40–60 | nothing, STLs ready |
| G | Misc | M2×8 self-tapping screws, PH 2-pin pigtails, Kapton, foam pads | — | 15–25 | nothing, ready |

**Estimated total for the prototype run: $600–875** in hard costs, plus freight and duties (~$70).
That excludes engineering time and lab testing.

---

## B. Main board: JLCPCB PCB + PCBA

**Board**

| Option | Value |
|---|---|
| Layers | 4 |
| Dimensions | Ø38 mm round (routed outline) |
| Thickness | 1.6 mm |
| Material | FR-4 TG155 |
| Surface finish | ENIG (needed for the 0.4 mm pitch QFN-56 and QFN-16) |
| Min track/space | 0.1 / 0.1 mm (JLC 4-layer standard) |
| Min via | 0.3 / 0.15 mm (via-in-pad for the RP2040 EP, plugged and capped) |
| Panelisation | 2 × 3 panel with rails and mouse bites (JLC can panelise) |
| Quantity | 12 boards (one 2 × 3 panel × 2) |

**Assembly**

| Option | Value |
|---|---|
| Type | Standard PCBA, **both sides**. The parts need ~104 % of one side of a Ø38 mm disc, so passives and SOT-23s go underneath (1.6 mm clearance to the cover) |
| Bottom side | SW1 (TS-1187A), pogo pads, ~60 passives/SOT-23s. Second-side setup ≈ +$25–40 |
| BOM | `hardware/bom/main_jlc.csv` (LCSC codes verified 30 Oct 2026, all in stock) |
| CPL | from layout |
| Programming | not needed. UF2 over USB-C after delivery |
| Unique Extended parts | ≈ 17 on this board (feeder fee ≈ $3 each) |

Estimate: PCB ≈ $25–45, setup + 2 stencils ≈ $45, feeder fees ≈ $50, parts ≈ $95 (12 × $7.9),
joints ≈ $10 → **$230 ± 40**, plus shipping.

## C. LED flex: JLCPCB flex PCB + PCBA

| Option | Value |
|---|---|
| Type | 2-layer flex, polyimide 25 µm, 1 oz copper (rolled-annealed) |
| Outline | LED field 33 × 117 mm (wraps the 11 mm triangular mast) + tail 6.5 × 95 mm to the main board (`flex.kicad_pcb`) |
| Stiffener | 0.2 mm PI at the 8 gold fingers (0.5 mm pitch). Total finger thickness 0.30 mm ±0.03 for Hirose FH12 |
| Coverlay | yellow PI. White coverlay over the LED field is preferred (reflects light into the diffuser) |
| Finish | ENIG |
| Bend areas | three 120° folds along the mast edges, no vias or pads within 1 mm of a fold line |
| Assembly | 24 × L128-RNG1003500000 (consigned), 24 × 22 Ω 0402, 1 × NCP15XH103F03RC |
| BOM | `hardware/bom/led_jlc.csv` |

Estimate: flex PCB ≈ $60–110 for 12 at this length, assembly ≈ $40–60, consign handling ≈ $10
→ **$140–220**. Ask JLC to confirm the minimum bend radius over the folds. If they flag it,
fall back to three rigid 0.8 mm FR-4 strips joined by a short flex jumper.

## D. LEDs: Digi-Key / Mouser, consigned to JLCPCB

| Line | MPN | Qty | Note |
|---|---|---|---|
| 1 | Lumileds L128-RNG1003500000 (LUXEON 2835 Color Line, Red-Orange) | 320 | 24 per lamp × 12 + 10 % |
| alt | Cree LED JE2835ARO-N-0001A0000-N0000001 | — | same 2835 footprint, 615 nm. Second source, not mixed within one lamp |

Request a **single wavelength bin across the whole reel** (ask for the 610–615 nm dominant bin if
a peak near 620 nm matters more than brightness). Ship direct to the JLCPCB consignment address
from your JLC account ("Parts Manager → Consigned parts").

## E. Battery cells

Twelve 21700 cells, ~5,000 mAh, **with nickel solder tabs spot-welded by the vendor**. Never solder
to a bare cell. Good low-drain choices: Samsung 50S, Molicel P50B, Molicel M50A, Samsung 50E.
Vendors that weld tabs to order in the US: 18650BatteryStore (tab service), IMR Batteries. Then
solder a 2-pin JST-PH pigtail (24 AWG, ~90 mm) to the tabs, insulate with Kapton and fish paper,
and check polarity before plugging in. The main board has its own DW01A protection, so
unprotected (flat-top) cells are correct here.

For production, buy finished **1S1P packs** (cell + tabs + leads + connector, with UN 38.3 and
IEC 62133 documents) from a pack assembler instead.

## F. Enclosure prints

Per lamp: `lower_body`, `bottom_cover`, `led_mast`, `diffuser`, one `sleeve_*`, `top_cap`
(all in `mechanical/stl/`). Copper silk PLA for the visible parts (≈ 60 g), natural PETG for the
diffuser (≈ 11 g), white PLA/PETG for the mast (≈ 5 g).

---

## Copy-paste RFQ text (for a second quote, e.g. PCBWay)

> Please quote PCB fabrication and turnkey assembly for two boards for a battery-powered LED
> lamp, quantity 12 each:
> (1) Ø38 mm round 4-layer FR-4 1.6 mm ENIG main board, RP2040 QFN-56 (0.4 mm) and
> BQ24073 QFN-16, ~117 placements on both sides;
> (2) 2-layer polyimide flex, 33 × 110 mm LED field plus 5 × 100 mm tail with 8 gold fingers at
> 0.5 mm pitch and a PI stiffener to 0.30 mm total thickness, 49 placements including 24 consigned
> 2835 LEDs. BOMs with exact MPNs attached. Do not substitute the LEDs, the charger, the DAC
> (MCP4728) or the op-amps (TLV9002) without written approval. Please list PCB, components,
> setup, stencil and shipping separately, with lead time.