Cameo Cutter Makes SMD Stencils

You never know what you might find in an arts and craft store. A relatively recent addition to crafting is automatic cutting machines like the Cricut and Cameo cutters. These are typically used to cut out shapes for scrapbooking, although they will cut or engrave almost anything thin. You can think of them as a printer with a cutting blade in place of the print head. [Mikeselectricstuff] decided to try a Cameo cutter to produce SMD stencils. The result, as you can see in the video below, is quite impressive.

If you’ve ever wanted to do SMD soldering with a reflow oven, stencils are invaluable for putting solder paste on the board where you want it quickly. The board [Mike] has contains a boat-load (over 2,000) of LEDs and dropping solder on each pad with a syringe would be very time consuming (although he did do some touch up with a syringe).

The board he’s using doesn’t have any extreme fine-pitched parts. However, he did some test patterns and decided he could get down to a finer pitch, especially with a little tweaking. However, the stencil he used didn’t need any changes. All he did was export the solder paste layer as a DXF and bring it straight into the Cameo software.

This isn’t the first time we’ve seen one of these cutters pressed into stencil service. You can also get some use out of your 3D printer.

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The Long Tail Of DIY Electronics

These are the Golden Years of electronics hacking. The home DIY hacker can get their hands on virtually any part that he or she could desire, and for not much money. Two economic factors underlie this Garden of Electronic Eden that we’re living in. Economies of scale make the parts cheap: when a factory turns out the same MEMS accelerometer chip for hundreds of millions of cell phones, their setup and other fixed costs are spread across all of these chips, and a $40 million factory ends up only costing $0.50 per unit sold.

But the unsung hero of the present DIY paradise is how so many different parts are available, and from so many different suppliers, many of them on the other side of the globe. “The Internet” you say, as if that explains it. Well, that’s not wrong, but it’s deeper than that. The reason that we have so much to choose from is that the marginal cost of variety has fallen, and with that many niche products and firms have become profitable where before they weren’t.

So let’s take a few minutes to sing the praises of the most important, and sometimes overlooked, facet of the DIY economy over the last twenty years: the falling marginal cost of variety.

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CNC Machine Boasts Big Bed, Impressive Power From Off-the-Shelf Parts

A lot of homebrew CNC machines end up being glorified plotters with a router attached that are good for little more than milling soft materials like wood and plastic. So if you have a burning need to mill harder materials like aluminum and mild steel quickly and quietly, set your sights higher and build a large bed CNC machine with off-the-shelf components.

With a budget of 2000 €, [SörenS7] was not as constrained as a lot of the lower end CNC builds we’ve seen, which almost always rely on 3D-printed parts or even materials sourced from the trash can. And while we certainly applaud every CNC build, this one shows that affordable and easily sourced mechatronics can result in a bolt-up build of considerable capability. [SörenS7]’s BOM for this machine is 100% catalog shopping, from the aluminum extrusion bed and gantry to the linear bearings and recirculating-ball lead screws. The working area is a generous 900 x 400 x 120mm, the steppers are beefy NEMA23s, and the spindle is a 3-kW VFD unit for plenty of power. The video below shows the machine’s impressive performance dry cutting aluminum.

All told, [SörenS7] came in 500 € under budget, which is a tempting price point for a machine this big and capable.

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Wireless Terminal Over ESP8266

From debug messages to the fundamental ‘hello world’, serial communication does it all over three little wires. Now imagine being able to cut the cord to your next microcontroller project and use your phone as a VT100 terminal. This was the premise of [Ondřej Hruška]’s Wireless Terminal Project where he took an ESP8266  and added an in-browser terminal emulator which can be accessed over WiFi. The final hardware uses an ESP-01 module mounted atop a breadboard adapter with a 3.3V LDO, protection circuitry for the pins and under-voltage disable.

The firmware is based on [SpriteTM]’s libesphttpd code which was modified to include the VT100 escape sequence parser. The parser, in turn, was coded as a state machine and compiled using Ragel which simplifies such projects greatly. When you access the tiny web server, the loaded webpage starts to communicate over web sockets to the ESP-01. Key-presses from the terminal are sent to the buffer and onto the parser and control logic. The characters are then passed to the hardware UART lines at 115200bps and if an escape sequence is detected, the corresponding action is executed instead.

[Ondřej Hruška] shares the code as well as a user manual in PDF for anyone who would like to try it out and help improve the project. With a little inspiration on learning about state machines, you could extend the project to your own use case as well.

Thanks for the tip [Marco Saarloos]