Copper Foil Makes Music–With a Little Help

Craft stores are often the source of odd inspiration. In the stained glass section, we’ve seen the copper foil, and even used it to prototype some RF circuits on the tops of shoeboxes. However, we could never get a good method for connecting ICs to the relatively thick foil. [Bryan Cera] did it though. His paperSynth¬†uses some paper and cardboard for a substrate, copper foil, and an ATtiny CPU to make music. You can see the device in operation in the video, below.

The copper foil is sticky and it isn’t conductive on the back, so anywhere the foil is supposed to touch, you need a blob of solder. We wouldn’t trust the insulation by itself to cross wires, but with a bit of insulating material between–a piece of paper or electrical tape, for example–you could probably cross with impunity. For an RF circuit, you might even make low-value capacitors like that.

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Cutting out your own breakout boards

[Caleb] needed to use some surface mount components when prototyping. Instead of buy a breakout board he made one himself without doing any etching. The process he shows off in the video after the break uses copper tape to layout the traces for the board. It’s quite an interesting method which requires a sharp knife and a steady hand.

He used regular protoboard as a substrate and applied a layer of copper tape on the side without copper pads. From there he poked holes for the DIP pin headers. Now it’s time to do some cutting. [Caleb] removed the band of copper that would fall in between the pins of the surface mount device. He then tacked¬†it in place with one dot of solder and drew the traces from the part to the pin headers. After removing the part he cut out the waste in between each line he drew with marker. What he’s left with is a set of thin traces that connect each pin of the surface mount component to the corresponding through-hole pin header.

This is very time-consuming, but then again so is soldering jumper wires to small-pitch components.

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