Refine repository structure for KiCad 9 optimization

- Add dedicated /kicad/ directory with organized subdirectories for libraries, schematics, gerbers, plots, and backups
- Create comprehensive KiCad 9 library structure (symbols, footprints, 3D models)
- Add manufacturing-ready directories for production files (gerbers, drill, pick-and-place)
- Update all README files with KiCad-specific documentation and workflows
- Add KiCad-optimized .gitignore file for proper version control
- Create KICAD-PROJECT-TEMPLATE.md comprehensive usage guide
- Add hardware assembly documentation and BOM management
- Include detailed manufacturing file generation instructions
- Add docs structure with design-notes and user-manual directories
- Provide complete workflow from design to manufacturing with quality checklists
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# /hardware/assembly
Assembly drawings and instructions for your KiCad project.
## Purpose
This directory contains assembly-related documentation and drawings that help with the physical construction of your PCB:
- Assembly drawings
- Component placement guides
- Assembly instructions
- Pick and place references
## File Types
- **`.pdf`**: Assembly drawings and instructions
- **`.png/.jpg`**: Assembly photos and diagrams
- **`.txt/.md`**: Text-based assembly instructions
- **`.csv`**: Component placement data
## Assembly Drawings from KiCad
1. Open your PCB (`.kicad_pcb`)
2. Go to **File → Plot**
3. Select layers for assembly:
- F.Fab (Front Fabrication)
- B.Fab (Back Fabrication)
- F.SilkS (Front Silkscreen)
- B.SilkS (Back Silkscreen)
4. Enable "Plot footprint values" and "Plot reference designators"
5. Set output directory and plot
## Recommended Assembly Files
```
assembly/
├── ProjectName-Assembly-Top.pdf # Top side assembly drawing
├── ProjectName-Assembly-Bottom.pdf # Bottom side assembly drawing
├── ProjectName-Assembly-Guide.pdf # Complete assembly instructions
├── ProjectName-Placement.csv # Component placement coordinates
├── assembly-photos/
│ ├── step1-power-components.jpg
│ ├── step2-mcu-section.jpg
│ └── step3-connectors.jpg
└── instructions/
├── assembly-checklist.md
├── soldering-notes.md
└── testing-procedure.md
```
## Assembly Drawing Guidelines
- Include component reference designators
- Show component values where helpful
- Indicate polarity for polarized components
- Mark pin 1 locations for ICs
- Include assembly notes and warnings
- Use different colors for different component types
## Assembly Instructions Content
- **Component list**: What components go where
- **Assembly order**: Sequence for efficient assembly
- **Special procedures**: Unique assembly steps
- **Soldering notes**: Temperature, time, flux requirements
- **Testing points**: Where to probe during assembly
- **Troubleshooting**: Common issues and solutions
## Pick and Place Data
Generate component placement data for automated assembly:
1. In KiCad PCB editor, go to **File → Fabrication Outputs → Component Placement**
2. Configure format (CSV recommended)
3. Include position, rotation, and side information
4. Save to this directory
## Quality Control
- **Assembly checklist**: Step-by-step verification
- **Visual inspection**: What to look for
- **Electrical testing**: Basic functionality tests
- **Rework procedures**: How to fix common mistakes
## Best Practices
- Create assembly drawings at 1:1 scale when possible
- Use clear, high-contrast colors
- Include revision information
- Document any special tools required
- Provide multiple views for complex assemblies
- Include photos of completed assembly