The Credit Card Sized GameBoy


Think you’ve seen every possible type of Arduino based hand held video game? [Kevin] managed to coax something new out of the theme with a very clever credit card sized console that uses some very interesting construction techniques.

The inspiration for this project began when [Kevin] dropped an SMD resistor into a drill hole on a PCB. This resistor fell right through the hole, giving him the idea creating a PCB with milled cutouts made to fit SMD components. With a little experimentation, [Kevin] found he could fit a TQFP32 ATMega328p  - the same microcontroller in the Arduino – in a custom square cutout. The rest of the components including a CR2016 battery and OLED display use the same trick.

The rest of the design involved taking Adafruit and Sparkfun breakout boards, and modifying the individual circuits until something broke. Then, off to Eagle to create a PCB.

[Kevin]‘s experiment in extremely unusual PCB design worked, resulting in a credit-card sized “Game Boy” that’s only 1.6 millimeters thick. The controls are capacitive touch sensors and he already has an easter egg hidden in the code; enter the Konami code and the Hackaday logo pops up to the tune of [Rick Astley]‘s magnum opus.

Now [Kevin] is in a bit of a bind. He’d like to take this prototype and turn it into a crowd sourced campaign. In our opinion, this “Game Boy in a wallet” would probably do well on a site like Tindie, but any sort of large scale manufacturing is going to be a rather large pain. If you have any wishes, advice, of complaints for [Kevin] he’s got a few links at the bottom of his project page.

Valentine’s PCBs To Make Your Heart Melt


Have you ever sat in bed, staring at a bottle of Iron III Chloride, and thought “I should do something with that…”? [Tobias] has. He wanted to use his tinkering skills to make his girlfriend happy, so he decided to make this beautiful etched PCB that professes his love to her.

The cool thing about this project is that [Tobias] has never etched a PCB, or even worked with SMD parts before! After designing the PCB layout on his computer, he printed it out on an inkjet transparency film and applied it to his PCB. After 14 minutes of exposure he then put the board into development fluid for about 60 seconds — it was starting to look good already! He then pulled out his trusty bottle of Iron III Chloride and began the etching process.

Once the board was etched, he soldered 18 red PLCC-2 LEDs in place, each with its own 330Ohm resistor. Not content with a simple on/off switch, [Tobias] decided to program a Trinket with a voltage regulator and mosfet to have it pulse on and off, similar to a beating heart! The finished project looks great, and we’re sure his girlfriend will love it.

Another bonus to doing something geeky like this for your loved ones means it will increase their acceptance of tools laying about, and half-finished projects that aren’t quite as pretty!

From Schematic to PCB in Four Hours


Last super bowl Sunday, instead of checking the game, [Mattw] decided to extend a design and make a PCB of a trinket clone. [Mattw] altered a trinket clone design by [Morgan Penfield Redfield] to shrink it down, perforated the USB connector to allow for easy removal and put most of the parts on a single layer.

After finalizing the design, [Mattw] put it into the LPKF Protolaser S that Seattle’s Metrix Create Space has. For those of you who don’t know, the LPKF protolaser uses a laser to directly ablate off the copper from the boards.  This makes prototyping much faster without the need for a lot of nasty chemicals.

About six minutes in the Protolaser, some component placement by hand followed by a run through their reflow oven and [Mattw] had three boards ready to be tested. All told, about 4 hours from start to finish.

The end circuit looks great and the LPKF protolaser gives us a case of serious tool envy. If you’re like us and don’t have access to the fancy laser you might try our hand at this high-resolutino photo-etch process.

[via reddit]

Fail of the Week: Oil Expeller and Hasty PCB Layout


This Fail of the Week is a twofer. On the left we have an attempt to heat the output of an oil expeller. After a bountiful crop of sunflower seeds [Mark] picked up the oil expeller to make is own cooking oil. He tried to use the soldering gun as a heat source but after just a couple of minutes of on-time it melted the soldering iron’s plastic case. He’s looking for an alternate heat source but we wonder why he can’t just ditch the plastic and bolt this to a heat sink?

To the right is the product of hasty PCB layout. [Andrew] needed a USB to GPIO converter to use with his Android stick. He had built several of these before, etching the PCBs himself. But now he didn’t have the time to do his own etching and figured he could lay out a revision of the board and have it fabbed. Turns out this isn’t the time saver he had hoped. Problems with the location of silk screen labels aren’t a huge deal, but the ‘V’ in the board where his USB connector is located blocked any cable he tried to plug in. A bit of cutting solved that but he also had to deal with spring terminals whose leads wouldn’t fit the diameter of holes drilled in the board. We always print out the Gerbers and compare the footprints to our parts before submitting to the fab house. But we’re not sure we would have caught the USB cable clearance issue doing it that way. What checklists do you use before submitting your own boards?

2013-09-05-Hackaday-Fail-tips-tileFail of the Week is a Hackaday column which runs every Wednesday. Help keep the fun rolling by writing about your past failures and sending us a link to the story – or sending in links to fail write ups you find in your Internet travels.

Laser-Based PCB Printer


Being able to create PCB’s at home is a milestone in the DIYer’s arsenal. Whether you physically mill or chemically etch boards, it’s a tricky task to perfect. [Charlie & Victor] are working towards a solution to this complicated chore. They call their machine the DiyouPCB. DiyouPCB is an open source PCB etching project consisting of both hardware and software components.

The project is based on using a Blue Ray optical pickup. The pickup was used in its entirety, without any modification, to simplify the build process. In order to use the stock pickup, [Charlie & Victor] had to reverse engineer the communication protocol which also allowed them to take advantage of the auto-focus feature used while reading Blue Ray discs. The frame of the machine is reminiscent of a RepRap, which they used to do preliminary testing and laser tuning. The X and Y axes run on brass bushings and are belt driven by stepper motors which are controlled by an Arduino through a specially designed DiyouPCB Controller Shield.

[Read more...]

[CNLohr] Demos His Photoetch PCB Process


If you’re going to learn something, it only makes sense to learn from a master. [CNLohr] is known around these parts for his fablous PCBs, and he’s finally started to document his entire fabrication process.

[CNLohr] is using a photoetch process, where a mask is created with a laser printer on overhead transparencies. He covers the copper clad boards with a Riston photosensitive mask—available here, and they accept Bitcoin—sent through a laminator, and exposed with the laser printed mask and a UV grow bulb. After the mask has developed, [CNLohr] drops his boards into a ferric chloride bath that eats away the unexposed copper. He then removes the photomask with acetone and cuts the boards with a pair of aircraft snips, and they’re ready to be soldered up with components.

Yes, home PCB etching tutorials are pretty much a solved problem, but [CNLohr]‘s work speaks for itself. He’s also the guy who made a microcontroller/Linux/Minecraft thing on a glass microscope slide. Learning from a guy with these skills means you’re learning from one of the best.

Video below, and there’s also a video going over the design of a PCB using KiCAD (!) and TopoR (!!!) available here.

[Read more...]

Toner Transfer PCBs, Double Sided, With Color Silkscreen


Making a few PCBs with the toner transfer method is a well-known technique in the hacker and maker circles. Double-sided PCBs are a little rarer, but still use the same process as their single-sided cousins. [Necromancer] is taking things up a notch and doing something we’ve never seen before – double-sided PCBs made at home, with color silkscreens, all make with a laser printer.

For laying down an etch mask, [Necro] is using a Samsung ML-2167 laser printer and the usual toner transfer process; print out the board art and laminate it to some copper board.

The soldermasks use a similar process that’s head-slappingly similar and produces great results: once the board is etched, he prints out the solder mask layer of his board, laminates it, and peels off the paper. It’s so simple the only thing we’re left wondering is why no one thought of it before.

Apart from the potential alignment issues for multiple layers, the only thing missing from this fabrication technique is the ability to do plated through holes. Still, with a laser printer, a laminator, and a little bit of ferric or copper chloride you too can make some very nice boards at home.