Using A Fiber Laser To Etch 0.1 Mm PCB Traces

March 24, 2026 by Maya Posch 12 Comments

Creating PCBs at home is quite easy these days (vias not withstanding), but even the best DIY methods usually can’t match the resolution offered by commercial PCB production lines. Large traces are easy enough to carve out of copper-backed FR1 or FR4 with even a mill, what if you need something more like 100 µm sized traces with similar clearance? This is what [Giangix] has been experimenting with, using both a fiber laser and chemical etching to see what approach gives the best results.

The thin copper clad boards are put on the 20 Watt fiber laser and held in place with the vacuum table that [Giangix] previously made, using the power of suction to make sure the board doesn’t move. The used laser specifies a minimum line width of 0.01 mm, so that’s clearly fine enough to engrave away the chemical resist layer that is sprayed on top of the copper layer.

After some experimentation, it was found that increasing the trace clearance between the 0.1 mm traces to a hair above 0.1 mm was necessary for the subsequent chemical etching step to work the best, as otherwise some copper was still likely to remain. The chemical etching bath mixture consists of hydrochloric acid and hydrogen peroxide, in a ratio of 2 mL water to 2 mL 30% HCl and 2 drops of 35% H2O2. This is agitated for 90 s to get a pretty good result.

Although the final resistance measurements on the traces is a bit higher than theoretical, comments suggest that maybe some of the copper got removed along with the removal of the resist layer. Perhaps the most interesting question here is whether directly ablating the copper using the fiber laser would give even better results and bypass the etching chemicals.

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Low Self-Discharge, High-Voltage Supercapacitors Using Porous Carbon

March 23, 2026 by Maya Posch 13 Comments

Supercapacitors rely mostly on double-layer capacitance to bridge the divide between chemical batteries and traditional capacitors, but they come with a number of weaknesses. Paramount among these are their relatively low voltage of around 2.7 V before their electrolyte begins to decompose, as well as their relatively high rates of self-discharge. Here a new design using lignin-derived porous carbon electrodes and a fluorinated diluent was demonstrated by [Shichao Zhang] et al., as published in Carbon Research, that seems to address these issues.

Most notable are the relatively high voltage of 4 V, an energy density of 77 Wh/kg and a self-discharge rate that’s much slower than that of conventional supercapacitors. In comparison with these supercapacitors, these demonstrated versions are also superior in terms of recharge cycles with 90% of capacity remaining after 10,000 cycles, which together with their much higher energy density should prove to be quite useful.

This feat is accomplished by using lignin as the base for the carbon electrodes to make a highly porous surface, along with the new electrolyte formulation consisting of a lithium salt (LiBF₄) dissolved in sulfolane with TTE as a non-solvating diluent. The idea of using lignin-derived carbon for such a purpose has previously been pitched by [Jia Liu] et al. in 2022 and [Zhihao Ding] in 2025, with this seemingly one of the first major applications we may be seeing.

Although the path towards commercialization from a lab-assembled prototype is a rough one, we may be seeing some of these improvements come to supercapacitors near you sooner rather than later.

Storing Solar Energy As Ice For Air Conditioning

March 22, 2026 by Maya Posch 84 Comments

Thermal energy storage is pretty great, as phase-change energy storage is very consistent with its energy output over time, unlike chemical batteries. You also get your pick from a wide range of materials that you can either heat up or cool down to store energy. Here, the selection is mostly dependent on how you wish to use that energy at a later date. [Hyperspace Pirate] is mostly interested in cooling down a house, on account of living in Florida.

As can be seen in the top image, the basic setup is pretty straightforward. PV solar power charges a battery until it’s fully charged. Then an MCU triggers a relay on the AC inverter, which then starts the cooling compressor on the water reservoir. This proceeds to phase change the water from a liquid into ice. The process can later be reversed, which will draw thermal energy out of the surrounding air and thus provide cooling.

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How A Belkin USB Charger Pulls Off A 3 Milliwatt Standby Usage

March 22, 2026 by Maya Posch 20 Comments

Belkin charger standby power. (Credit: Denki Otaku, YouTube)

A well-known property of wall warts like power bricks and USB chargers is that they always consume some amount of power even when there’s no connected device drawing power from them. This feels rather wasteful when you have a gaggle of USB chargers constantly plugged in, especially on a nation-sized scale. This is where a new USB-C wall charger by Belkin, the BoostCharger Pro, is interesting, as it claims ‘zero standby power’, which sounds pretty boastful and rather suspect. Fortunately, [Denki Otaku] saw fit to put one to the test and even tear one down to inspect the work of Belkin’s engineers.

Naturally, no laws of physics were harmed in the construction of the device, as ‘zero standby power’ translated from marketing speak simply means ‘very low standby power usage’, or about 3 milliwatt with 0.3 mA at the applied 100 VAC.

Fascinatingly, plugging in an e-marker equipped USB-C cable with no device on the other end caused this standby usage to increase to about 30 mW, clearly disabling the ‘zero standby’ feature. With that detail noted, it was time to tear down the charger, revealing its four PCBs.

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Reviving A Cursed Sun SPARCstation IPX

March 21, 2026 by Maya Posch 21 Comments

SPARCstation IPX running Solaris 2.6. (Credit: This Does Not Compute, YouTube)

The best part about retro computing is the idea that you’ll save some poor system from being scrapped and revive it to a working state, at which point you can bask in the glory of a job well done. That’s when reality often strikes hard, and you find yourself troubleshooting a maddening list of issues as you question everything about your life choices. Such was the case with [This Does Not Compute] over at YouTube with a Sun SPARCstation IPX that decided to put up a big fight.

This is the second video of a series. In the first installment, the PSU was repaired, and a boot failure was diagnosed. The system’s onboard diagnostic led to the assumption that one of the 8 kB SRAM ICs was defective. You can readily get SRAM replacements, so it seemed to be an easy fix. Unfortunately, the fun was only beginning as the system reported the exact same error after the SRAM was replaced.

After flipping a virtual table, the mainboard was swapped with a donor one from a scrapped laptop system. With this, it booted, but the video output showed only vertical lines. Obviously, the solution here was to insert a replacement video card, which not only fixed the display output but also demonstrates once again that you can fix many vintage computing issues by simply replacing hardware.

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Slug Algorithm For On-GPU Rendering Of Fonts With Bézier Curves Now In Public Domain

March 20, 2026 by Maya Posch 15 Comments

The Slug Algorithm has been around for a decade now, mostly quietly rendering fonts and later entire GUIs using Bézier curves directly on the GPU for games and other types of software, but due to its proprietary nature it didn’t see much adoption outside of commercial settings. This has now changed with its author, [Eric Lengyel], releasing it to the public domain without any limitations.

Originally [Eric] had received a software patent in 2019 for the algorithm that would have prevented anyone else from implementing it until the patent’s expiration in 2038. Since 2016 [Eric] and his business have however had in his eyes sufficient benefit from the patent, making it unnecessary to hold on to it any longer and retain such exclusivity.

To help anyone with implementing their own version of the algorithm, there is a GitHub repository containing reference shader implementations with plenty of inline comments that should help anyone with some shader experience get started.

Although pretty niche in the eyes of the average person, the benefits of using on-GPU rendering of elements like fonts are obvious in terms of rendering optimization. With this change open source rendering engines for games and more can finally also use it as well.

Thanks to [Footleg] for the tip.