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The general process of circuit board assembly goes like this: You order your PCBs. You also order your components. For surface mount components, you apply solder paste to the pads, put the components on top, and then heat the board up so the solder paste flows and makes a bond. Then for through hole components you put the leads through the holes, and solder them with an iron or a solder wave or dip. Then you do an inspection for defects, program any microcontrollers, and finally test the completed board to make sure everything runs.
The tricky part is in volumes. If you’re only doing a few boards, it’s usually easiest to assemble them by hand. In the thousands you usually outsource. But new tools, and cheap hacked tools, have made it easier to automate small batches, and scale up into the thousands before outsourcing assembly.
In this new series which we’re calling Tools of the Trade we’ll be covering a variety of tools used for building products, and we’re starting with circuit board assembly. Let’s investigate our tools of the trade: solder paste dispensing. Continue reading “Tools Of The Trade – Solder Paste Dispensing”→
We wake up this morning to the news that Google’s deep-search neural network project called AlphaGo has beaten the second ranked world Go master (who happens to be a human being). This is the first of five matches between the two adversaries that will play out this week.
On one hand, this is a sign of maturing technology. It has been almost twenty years since Deep Blue beat Gary Kasparov, the reigning chess world champion at the time. Although there are still four games to play against Lee Sedol, it was recently reported that AlphaGo beat European Go champion Fan Hui in five games straight. Go is generally considered a more difficult game for machine minds to play than chess. This is because Go has a much larger pool of possible moves at any given time.
Does This Matter?
Okay, the news part of this event has been covered: machine beats man. Does it matter? Will this affect your life and how? We want to hear what you think in the comments below. But I’m going to keep going with some of my thoughts on the topic.
You’re still better at Ms. Pacman [Source: DeepMind paper in Nature]Let’s look first at what AlphaGo did to win. At its core, the game of Go is won by figuring out where your opponent will likely make a low-percentage move and then capitalizing on that choice. Know Your Enemy has been a tenet of strategy for a few millennia now and it holds true in the digital age. In addition to the rules of the game, AlphaGo was fed a healthy diet of 30 million positions from expert games. This builds behavior recognition into the system. Not just what moves can be made, but what moves are most likely to be made.
DeepMind, the company behind AlphaGo which was acquired by Google in 2014, has published a paper in Nature about their approach. They were even nice enough to let us read without dealing with a paywall. The secret sauce is the learning process which at its core tries to mimic how living entities learn: observe repetitively while assigning values to outcomes. This is key as it leads past “intellect”, to “intelligence” (the “I” in AI that everyone seems to be waiting for). But this is a bastardized version of “intelligence”. AlphaGo is able to recognize and predict behavior, then make choices that lead to a desired outcome. This is more than intellect as it does value the purpose of an opponent’s decisions. But it falls short of intelligence as AlphaGo doesn’t consciously understand the purpose it has detected. In my mind this is exactly what we need. Truly successful machine learning will be able to make sense out of sometimes irrational input.
The paper from Nature doesn’t go into details about Go, but it explains the approach of the learning system applied to Atari 2600. The algorithm was given 210×160 color video at 60Hz as an input and then told it could use a joystick with one button. From there it taught itself to play 49 games. It was not told the purpose or the rules of the games, but it was given examples of scores from human performance and rewarded for its own quality performances. The chart above shows that it learned to play 29 of them at or above human skill levels.
I was in a fit of nerd glee the first time I used tooling board. I’d used MDF for similar purposes before, and I doubt I ever will again. Called Renshape, Precision Board Plus, or that green stuff people on another continent buy; it’s all the same extremely useful, unfortunately expensive, stuff. It’s hard to pin down exactly what tooling board is. Most of the blends are proprietary. It is usually a very dense polyurethane foam, sometimes by itself, sometimes with a fine fiber filler.
What makes tooling board so good is its absolute dimensional stability and its general apathy to normal temperature swings. (It even comes in versions that can go through curing ovens.) It is impervious to humidity. It has good surface finish, and it machines perfectly without wearing down tools.
The CNC set-up I coaxed precision molds out of.
This stuff is really tops as far as machining goes. I got super precise molds out of a very basic CNC machine at the LVL1 hackerspace. Renshape cut easily at a high spindle speed, and put practically no load on the machine. Climb and conventional milling were equal load wise with no immediately perceivable difference in finish. In the end I hit the precision range of my cheap digital calipers: +-.005mm, when the temperature is right, the battery is a charged, and the planets align.
I like to do resin casting when I get serious about a part. If you are making a master mold, there’s nothing better than tooling board. I’ve used both Renshape 460 and Precision Board Plus. Both impart a very light matte pattern, equivalent to a light bead blast on an injection mold. There’s no finishing required, though I mistakenly bought Renshape 440 at first and had to sand it a little to get the finish I wanted.
Tooling board is great for masters in metal casting, and is often used in the industry for just that, especially if quick and accurate prototypes are needed. It’s also tough enough to last through a few rounds of metal stamping in the home shop.
If you are doing lay-up for carbon fiber, fiberglass, or leather, this is also a very good choice. It will be unaffected by the chemicals, heat, and vacuum you may use in the process. It is tough enough hold alignment pins for proper set-up without premature ovaling. It is also a very good choice for vacuum forming.
Tooling board is, unsurprisingly, really good for tooling. It’s a great material for soft-jaws, alignment fixtures, and assembly fixtures, especially if you are doing delicate precision assemblies.
If you’re made of money, tooling board can be used for models, signs and props. It sands, shapes, and files extremely well. It bonds well to a lot of substances. It also takes paint very well with none of the absorption properties of wood or MDF. Most professional model shops will use it. The one big flaw of tooling board is its price — this stuff is expensive. There’s no good DIY version that I’ve scrounged up so far. If you’re making a mold master, a fixture, or anything where you need tooling board’s properties and you are likely to get a few uses out of the board, then it’s probably worth it. Also, be careful of sellers selling plain “Renshape” it is probably going to be the lower grade Renshape 440 and not the more expensive Renshape 460 (or equivalent), where you start to really see the surface finish advantage of the material.
Tooling board is an industrial material. Typically you can call up a supplier and tell them what you’d like to do with it and they will be able to help. If you are making tools for carbon fiber quadcopter frame lay-up, let them know and they’ll have a formulation for that. If you are resin casting, there’s a formulation that gives superior surface finish.
It’s a pretty common material in the industrial scene, but I don’t see it a lot on the hobby scene. This is almost certainly due to its cost, as well as a shortage of small quantity re-sellers. (If someone starts selling assorted sizes on eBay for a reasonable price you have at least one buyer in me.) However, after using it in the niches it is designed for, I really don’t use anything else. I used to hack MDF to fit, but MDF is awful to paint, has no dimensional stability, and dulls tools really fast.
Are you a fan of tooling board? Have a good source? If you have anything to add, let us know in the comments.
If you read our recent feature about the Tal-y-Llyn Railway, the world’s first preserved line, you may have taken a while to watch the short film about the railway in the early 1950s. It was the work of an American film maker, [Carson “Kit” Davidson].
His other work includes some films that might be of interest to Hackaday readers, including one filmed in 1977: “100 Watts 120 Volts”. In it, he follows the manufacture of Duro-Test 100-watt light bulbs through all the stages of their assembly as neck, filament and envelope are brought together in strangely beautiful twentieth century production machinery.
Newly minted hams like me generally find themselves asking, “What now?” after getting their tickets. Amateur radio has a lot of different sub-disciplines, ranging from volunteering for public service gigs to contesting, the closest thing the hobby has to a full-contact sport. But as I explore my options in the world of ham radio, I keep coming back to the one discipline that seems like the purest technical expression of the art and science of radio communication – low-power operation, or what’s known to hams as QRP. With QRP you can literally talk with someone across the planet on less power than it takes to run a night-light using a radio you built in an Altoids tin. Now that’s a challenge I can sink my teeth into.
The most popular plastic for 3D printers is PLA – polylactic acid – a plastic that’s either derived from corn starch, inedible plant detritus, or sugar cane, depending where in the world it was manufactured. Being derived from natural materials, PLA is marketed as being biodegradable. You don’t need to worry about low-poly Pokemon and other plastic trinkets filling landfills when you’re printing with PLA, all these plastic baubles will return to the Earth from whence it came.
3D printers have been around for a few years now, and now objects printed in PLA have been around the sun a few times. A few of these objects have been completely forgotten. How’s that claim of being biodegradable holding up? The results are mixed, and as always, more data is needed.
A few weeks ago, [LazyGecko] found one of his first experiments in 3D printing. In 2012, he was experimenting with tie dying PLA prints by putting his prints in a jar filled with water and blue dye. This jar was then placed in the back of his cupboard and quickly forgotten. 3.5 years later, [LazyGecko] remembered his experiment. Absolutely nothing happened, save for a little bit of blue dye turning the print a pastel baby blue. The print looks and feels exactly like the day it came off the printer.
[LazyGecko]’s blog post was noticed by [Bill Waters], and he has one datum that points to PLA being biodegradable. In 2015, [Bill] printed a filter basket for his fish tank. The first filter basket worked well, but made a small design change a week later, printed out another, and put the first print in storage. He now has two nearly identical prints, one in constant use in a biologically interesting environment, the other sitting on a shelf for a year.
[Bill]’s inadvertent experiment is very close to the best possible experimental design to make the case for PLA biodegradability. The 3D printed filter basket in constant use for a year suffered significant breakdown, and the honeycomb walls are starting to crumble. The ‘inert’ printed filter basket looks like it just came off the build plate.
If that’s not confusing enough, [Bill] also has another print that has spent a year in a fish tank. This end cap for a filter spray bar didn’t see any degradation, despite being underwater in a biologically active environment. The environment is a little different from a filter basket, though; an aquarium filter is designed to break down organics.
To answer the question, ‘is PLA biodegradable,’ the most accurate answer is, ‘maybe’. Three data points in uncontrolled environments isn’t enough to draw any conclusions. There are, undoubtedly, more forgotten 3D prints out there, and more data to back up the claim of PLA being biodegradable.
This is where you come in. Do you have some forgotten prints out there? Your input is needed, the fruits of your labors are evidence, your prints might be decaying and we want to know about it below.
For the last few decades, the computer keyboard has been seen as just another peripheral. There’s no need to buy a quality keyboard, conventional wisdom goes, because there’s no real difference between the fancy, ‘enthusiast’ keyboards and ubiquitous Dell keyboards that inhabit the IT closets of offices the world over.
Just like the mechanic who will only buy a specific brand of wrenches, the engineer who has a favorite pair of tweezers, or the amateur woodworker who uses a hand plane made 150 years ago, some people who use keyboards eight or twelve hours a day have realized the older tools of the trade are better. Old keyboards, or at least ones with mechanical switches, aren’t gummy, they’re precise, you don’t have to hammer on them to type, and they’re more ergonomic. They sound better. Even if it’s just a placebo effect, it doesn’t matter: there’s an effect.
This realization has led to the proliferation of high-end keyboards and keyboard aficionados hammering away on boards loaded up with Cherry MX, Alps, Gateron, Topre, and other purely ‘mechanical’ key switches. Today, there are more options available to typing enthusiasts than ever before, even though some holdouts are still pecking away at the keyboard that came with the same computer they bought in 1989.
The market is growing, popularity is up, and with that comes a herculean effort to revive what could be considered the greatest keyboard of all time. This is the revival of the IBM 4704 terminal keyboard. Originally sold to banks and other institutions, this 62-key IBM Model F keyboard is rare and coveted. Obtaining one today means finding one behind a shelf in an IT closet, or bidding $500 on an eBay auction and hoping for the best.
Now, this keyboard is coming back from the dead, and unlike the IBM Model M that has been manufactured continuously for 30 years, the 62-key IBM Model F ‘Kishsaver’ keyboard is being brought back to life by building new molds, designing new circuit boards, and remanufacturing everything IBM did in the late 1970s. Continue reading “Reviving The Best Keyboard Ever”→
![You're still better at Ms. Pacman [Source: DeepMind paper in Nature]](https://hackaday.com/wp-content/uploads/2016/03/deepmind-atari2600-machine-learning.jpg)
