The bill of materials for Prototype IV has been complete. Here it is as an OpenOffice spreadsheet.

This BOM needs some work. Right now, the parts come out to be about $103 assuming we get some additional discount from a distributor for doing most of our buying through them. The $103 price is a 12% discount (too much?) from the 1000 part pricing. Mostly from DigiKey.

Also, every resistor and capacitor has been overspec'ed. Across the board, I put in 1/4 watt, 1% resistors and 25V capacitors (unless something greater was required). Also, I didn't go below a 1206 package because I don't think I can hand-solder anything smaller than that.

In addition, there are some expensive chips such as the voltage regulators and some of the line drivers that could easily be replaced once we have some more experience on the design. For now, I am overspec'ing to get a working board before I try to dial back the design.

Notice that the Powerline Modem is about 20% of the cost. This seems a little expensive but when you consider what it is doing for us it might be cheap. Jon has looked into replacing it with some algorithms on the MPC5200 but the OFDM stuff requires several inverse FFT's that start to tax the processor. He thinks the $20 is worth it right now. Notice that if we when with WiFi modules the cheapest we could add the feature is around $30. At that price, it would be an 'iffy' module at best (like a USB dongle). At $20, we believe we are going to get solid networkings. Time and testing will tell.

The Insteon people are now saying that they want $4 for their IN2680A chip. We were originally quoted something around $1.75 so that is quite a jump. For now, we are sticking with their chip. However, Jon is close to cloning the chip with some algorithms that run on the MPC5200. If that happens, we can reduce the Insteon feature the signal xmit and receive paths and a few other parts. That might knock $8 from the design.