Using A Fiber Laser To Etch 0.1 Mm PCB Traces

March 24, 2026 by Maya Posch 11 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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Building A Monitor Light Bar For Better Productivity

March 24, 2026 by Lewin Day 9 Comments

If you’re intending to work at your desk for long periods of time, good lighting is a must, as it can help stave off eye strain and mental fatigue. It was a desire for more comfortable productivity that drove [Jade] to whip up a monitor-mounted lighting system for her workstation.

The build uses an ESP32 to run the show, with a rotary encoder for manual control and firmware that allows the monitor light to be neatly integrated with Home Assistant. The light itself comes from light strips that feature both warm white and cold white LEDs. Simple MOSFETs are used to control the brightness of the LEDs and which of the warm and cold LEDs are activated at any time. Everything is wrapped up in a 3D printed housing that neatly sits on top of the monitor with the aid of a simple printed clamp. The LED strips also have a nice soft glow thanks to a strip of diffuser material that [Jade] snatched from an old television.

We love a good lighting build, from the work-focused to the creative and beautiful.

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From Zip To Nought: The Rise And Fall Of Iomega

March 24, 2026 by Lewin Day 62 Comments

If you were anywhere near a computer in the mid-to-late 1990s, you almost certainly encountered a Zip drive. That distinctive purple peripheral, with its satisfying clunk as you slotted in a cartridge, was as much a fixture of the era as beige tower cases and CRT monitors. Iomega, the company behind it, went from an obscure Utah outfit to a multi-billion-dollar darling of Wall Street in the span of about two years. And then, almost as quickly, it all fell apart.

The story of Iomega is one of genuine engineering innovation and the fickle nature of consumer technology. As with so many other juggernauts of its era, Iomega was eventually brought down by a new technology that simply wasn’t practical to counter.

The House That Bernoulli Built

Iomega was founded in Utah, in 1980, by Jerome Paul Johnson, David Bailey, and David Norton. The company soon developed a novel approach to removable magnetic storage based on the Bernoulli effect. The Bernoulli Box arrived in 1982, which was a drive relying on PET film disks spun at 1500 RPM inside a rigid, removable cartridge. The airflow generated by the spinning disk pulled the media down toward the read/write head thanks to the eponymous Bernoulli effect. While spinning, the disk would float a mere micron above the head surface on a cushion of air. If the power cut out or the drive otherwise failed, the disk simply floated away from the head rather than crashing into it—a boon over contemporary hard drives for which head crashes were a real risk. The Bernoulli Box made them essentially impossible. Continue reading “From Zip To Nought: The Rise And Fall Of Iomega” →

A hotend equipped with the bd_pressure sensor. The nozzle is facing upwards.

Direct Pressure Advance Measurement For Fast Calibration

March 24, 2026 by Tyler August 11 Comments

Some people love fiddling with their 3D printers, others love printing. Some fiddle so they can spend more time printing, which is probably where this latest project comes in: an automated pressure advance calibration tool by [markniu].

Most of us don’t take enough care with pressure advance (PA). But if you want absolutely perfect prints, its something you should be calibrating for every type filament in your collection. Some would argue, ideally every individual spool. While that sort of dialing in can be fun, it takes away from actually running off prints. Bambu printers automate PA by scanning the usual sort of calibration print, but that’s still a very indirect measurement. Why not, just advance the filament, and measure the pressure at the nozzle directly? That is what PA is meant to account for, after all: the pressure of the plastic in the hotend causing oozing and blobbing at corners.

Did we mention it connects via USB-C? That’s helpfully broken out well away from the heat with a ribbon cable.

[mark]’s solution comes very close to a direct measurement. It uses a strain gauge that sits directly on top of the heatbreak, with the sound logic that the strain there experienced will be directly proportional to the pressure inside, at least along the axis of flow. Instead of filling half the bed with lines, the calibration process instead is a ‘printer poop’ style extrusion that doesn’t take nearly as long, and seems to save plastic, too. Since this puts a strain gauge in your hotend, you also get the bonus of being able to use it for bed leveling if you should so desire.

[mark] is claiming sub-90 second calibration — as you can see in the demo video embedded below — versus over seven minutes for the indirect calibration print. The value is plugged directly into Klipper, assuming you configured everything correctly, which should be easy enough looking at the instructions on the GitHub. Continue reading “Direct Pressure Advance Measurement For Fast Calibration” →

Disposable Vape Becomes Breath-Activated Synth

March 24, 2026 by Lewin Day 8 Comments

Makers and hardware hackers have been collecting disposable vapes for some time now, usually to salvage their batteries or the unique displays many models now come with. But you can also repurpose them for other ends, such as playing music. [Becky Stern]’s vape synth is a perfect example of this.

The build started with an ElfBars BC5000 vape. [Becky] notes there may be similar models under different names out there that would work just as well. The vape is effectively gutted for parts, with the LiPo cell, USB charging board, and the low-pressure sensor the main things that remain. These parts are combined with a drop-in 555 synthesizer circuit complete with speaker, which has its pitch controlled by a series of six photoresistors. When the low pressure sensor is triggered by inhalation, the 555 circuit is triggered, and operates at a pitch depending on the resistance of the photoresistor stack.

The output of the vape synth is kind of shrill, and frankly a little bit annoying — which is somehow rather fitting for what it is. If you want to make a better-sounding synth at home, we’ve featured such projects, you’re just unlikely to fit them entirely within the housing of a disposable vape.

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Venus Flytrap Takes Ride Through A Particle Accelerator

March 23, 2026 by Ian Bos 12 Comments

In the blue corner, we have the VENUS FLYTRAP! In the red corner, we have the underdog of the century, AN ENTIRE PARTICLE ACCELERATOR. Yes, you read that right. When you have a particle accelerator, it’s only second nature to throw anything you can into it. That’s why [Electron Impressions] put a poor fly-eating trap into their accelerator.

Chloride and potassium ions leaving cause osmotic pressure in neighboring cells

The match-up isn’t quite as arbitrary as it might seem at first. The flytrap’s main mechanism of trapping and digesting insects relies heavily on intracellular ion movement. Many cells along the inside of the trap have hair-activated calcium channels that respond to a fly landing on its surface. This ion movement then creates an action potential, which propagates along the entire surface, triggering closing. As the potential moves across different cells, other ions leave and create osmotic pressure. This pressure is what creates the mechanical movement.

Of course, this makes it no surprise when the plant finds itself under the ionizing radiation that every single head closes at once. While this is a cool demonstration, there is a slight side effect of killing every single cell by ripping apart the trap’s DNA.

Well, who would have guessed that the underdog accelerator would have won… Anyways, the DNA being ripped apart is far from ideal for repeatability. If you want to learn more about genetic features that SHOULD be repeated, then make sure to check out the development of open-source insulin!

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