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BOM.md — ForgePCB v1 (Freeze-Level)

This BOM is aligned with Features F002–F005. It is procurement-ready at the class level. Part numbers may be selected later, but substitutions must respect invariants and be logged if they change behavior.


External Power

  • External AC/DC power supply: 24 V DC, 10 A (≈240 W), reputable brand class (Mean Well / Delta / TDK)

Power PCB

Input & Protection

  • Locking high-current DC panel connector (≥10 A @ 24 V)
  • Blade fuse holder (ATO/ATC)
  • 10 A blade fuse

Conversion

  • Buck converter: 24 V → 5 V, 5 A capability
  • Buck converter: 24 V → 3.3 V, 3 A capability

Protection / Switching

  • eFuse channels (programmable, latch-off): 3 channels
    • 5 V rail
    • 3.3 V rail
    • Variable bay output

UI

  • Rocker switches (rail enable via eFuse enable): 2
  • Momentary push buttons (fault reset): 2
  • LEDs:
    • Rail ON: 2
    • Rail FAULT: 2
    • Variable FAULT: 1

Variable Power Bay

  • Adjustable DC-DC module 0–24 V, ≥3 A, with display and its own enable
  • Banana jacks: red + black (pair)

Signal/Backbone PCB (DBB)

Headers (2.54 mm)

  • I²C 1×6
  • UART 1×6
  • SPI 2×5
  • RS-485 1×6
  • Logic analyzer 2×12 (16 channels + grounds)

Switches

  • DIP switch banks for:
    • I²C pull-ups enable + 3.3/5 selection
    • RS-485 TERM/BIAS/VLOGIC selection

Passives / Protection

  • I²C pull-up resistors footprints
  • RS-485 termination resistor footprint (120 Ω)
  • RS-485 bias resistors footprints
  • Optional TVS footprint on A/B lines

MCU Carriers (ESP32-S3 + RP2040)

  • Carrier PCBs: 80×120 mm, 4× M3 mounting: 2
  • Dupont header bank for 16 GPIO
  • Screw terminals: 8 GPIO + 2 GND per carrier (qty depends on terminal pitch/blocks)
  • Control buttons accessible (EN/BOOT, RUN)

USB & Debug

  • Internal USB 2.0 hub module: 4-port
  • Logic analyzer dongle (external): 16-channel class

Mechanical & Assembly

  • Embedded steel plate (isolated)
  • Isolation sheet (PET/FR4)
  • Magnetic mat (printer-bed style)
  • 2020 extrusion: rear + sides
  • Heat-set inserts: M3
  • M3 fasteners/standoffs
  • Ferrules assortment
  • Power wire: 16–18 AWG
  • Dupont wires assortment