CAD, development hardware, and the insides
Initial development hardware
The initial development hardware - significantly different from the final hardware. The display board migrated to RP2350 from an STM32, got wider, and had some additional protection added. The main board got the full SD card + USB subsystem added, and a clock generator to feed it. Additional IO expander and minor improvements for protection got added as well. The button board went away entirely, as did the rigid interconnect (everything is now FFC).
Development bringup
The development board, during bringup. The clock generator has been bodged on to generate MCLK for the audio amplifier, it will eventually feed the USB hub and SD card reader as well to cut down on oscillator usage.
PCB Layout (Main)
Main PCB layout - all components on top side, routing mostly constrained to top / bottom layer. GND on layer 2/5, power on 3/4.
PCB Layout (ZM1000)
ZM1000 PCB Layout - all components on top side excluding the assembly standoffs. Logic routing on top layer, HV routing on inner layers with voiding to reduce risk of shorts.
Panel Render
The final panel as-fabricated. Some components were not SMT'd by the fab house due to availability - as shown in the as-delivered photo.
As-delivered panel
Main board and ZM1000 panel, as delivered. They were designed to panel together to save cost on feeder fees, but the savings were a small percentage of the total cost. Missing components were either for debugging or were not available to SMT - hot air / hot plate soldering of main inductor / HV capactitor / tube sockets happened after this.
The first form-factor setup
The boards were brought up on a 3D printed plate, allowing for probing and SWD + UART via 2 BlackMagic debug boards.
Final CAD Screenshot
The final CAD model, as exhibited (minus the side label).