Issues

	Issues	Solutions	Comments
1	A & D boards can't be mounted in the "Edge Cu block" position	Disassemble Cu block assemblies. Remove 12 screws connecting stages and 2 screws connecting motor driver.	Can be done, but reassembly takes a long time.
2	JTAG Connector in the "Edge Cu block" position collides with stage motor	Remove JTAG connector after programming initial firmware?
3	Poor grip on modules	Work in progress	The module connector on the back blocks existing tools like waver tweezers
4	If pre-attached, some of the flexes need to be bent and forced through a small opening; Or, poor grip on modules (see 3 above) and tight spaces make it very hard to attach the flex cables to the modules when they are nearly in place	Either pre-attach flexes to modules and maneuver / push flexes through small opening Or develop a handling tool (see 3 above)	Work in progress
5	Large spaces between PCBs and Cu cooling block	Use multiple layers of thicker (3mm) thermal filler If redesigned, the Cu blocks can be significantly thicker (≈5mm?) Or, lower profile connector between A and D boards?	Cooling might be more efficient with thinner thermal padding layers, especially in vacuum
6	Most pockets in Cu blocks are not necessary	Fill the pockets with extra thermal filler Or redesign to remove the extra pockets	A redesign might be better for high vacuum
7	Two screws block assembly of A board in the "Edge Cu block" position	Use low profile screws	Works great now
8	One row of components can't be cooled by the Cu block	Low power dissipation? Is cooling through the PCB sufficient?
9	Some

Camera

Initial assembly

The entire assembly with 2 Cu blocks and brazed Cu lines can't be disassembled. However, removing the Cu block assembly is possible by disconnecting:

And the assembly can be gently maneuvered out of the camera body:

Reassembly is likely to take a long time; the 3 stages and assembly have to be perfectly aligned.

JTAG Connector Collision in "Side Cu block" position

Note below, JTAG connector extending into the stage motor area

Handling real modules

Very small grip area on the edge, with connector on the back.

The flexes can be preinstalled and the modules lowered in place, connected, then fixed. However, pushing the flex connector in while having a poor grip is not ideal. Alternatively, the flex cables can be safely attached to the modules first, then bent and pushed in place, and only connected afterwards. To be checked when modules are available.

Large space between A and D boards and Cu cooling block

(see examples below: left shows large gap; right shows multiple 1mm thermal filler layers for matching)

Most pockets in Cu cooling block are not necessary

With the current Cu block thickness, most pockets can be removed. Only the transceiver and voltage regulator ones are necessary. (If going with a thicker Cu block, some pockets will be necessary).

Preparing Cu block for assembly (left) and matching D board with thermal filler (center, right):

Note the 3-4 mm layers of thermal fillers on the PCB and the 3mm layers of thermal fillers in the Cu block pocket.

Also, 3mm layers if thermal filler on the Analog board side:

Analog board can't be mounted in the "Edge Cu block" position

Using low profile screws works great (not shown)

One row of components can't be cooled directly by thermal filler in contact with the Cu block

Some tapped holes for attaching the PCBs to both copper plates in the TXI camera: they are randomly tapped either with the correct thread 4-40, or with a larger one (I suspect 6-32). The problem with the 6-32 tapped holes is that the 6-32 screws don't fit through the PCB holes and 4-40 ones are too small (they just slip inside and retapping is also out of question). By "random" I mean there is no correspondence between the same holes in the two different copper blocks. This is clearly a machining failure.