Guide: Why Etch A PCB When You Can Mill?

January 4, 2018 by Adil Malik 83 Comments

I recall the point I started taking electronics seriously, although excited, a sense of dread followed upon the thought of facing the two main obstacles faced by hobbyists and even professionals: Fabricating you own PCB’s and fiddling with the ever decreasing surface mount footprints. Any resistance to the latter proves futile, expensive, and frankly a bit silly in retrospect. Cheap SMD tools have made it extremely easy to store, place, and solder all things SMD.

Once you’ve restricted all your hobbyist designs/experiments to SMD, how do you go about producing the PCBs needed for prototyping? Personally, I dread the thought of etching my own boards. The process is laborious and involves messy chemicals and specially sensitized PCB’s — none of which interest me. I’ve only ever done it a few times, and have promised myself never to do it again. Professional but cheap PCB manufacturing is more like it board pooling services such as OSH park have made this both easy and affordable — if you can wait for the turnaround.

So what are the alternatives? If you are really serious about swift prototyping from your own Lab, I put forth the case of milling your own PCB’s. Read on as I take you through the typical workflow from design to prototype and convince you to put up with the relatively high start up cost of purchasing a PCB mill.

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JST Is Not A Connector

December 27, 2017 by Roger Cheng 45 Comments

When reading about cool projects and products, it’s common to see wiring plugs labelled “JST connector.” This looks fine until we start getting hands-on and begin hacking things together. Inevitably we find the JST connector from one part fails to fit in the JST connector of another. This is the moment we learn “JST” is not a connector specification. It is short for Japan Solderless Terminals Manufacturing Company, Ltd. A company whose history goes back to 1957 and their website (styled in 1999) lists hundreds of different types.

We can simplify to “JST connector” when chit-chatting about projects. But when it comes to actual hardware specification, that’s not good enough. Which JST connector?

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3D Printing The Final Frontier

December 18, 2017 by Tom Nardi 29 Comments

While down here there’s room for debate about the suitability of 3D printing for anything more serious than rapid prototyping, few would say the same once you’ve slipped the surly bonds of Earth. With 3D printing, astronauts would have the ability to produce objects and tools on-demand from a supply of inert raw building materials. Instead of trying to pack every conceivable spare part for a mission to Mars, replacements (assuming a little forward thinking on the part of the spacecraft designers) can be made to order out of the stock of raw plastic or metal kept on-board. The implications of such technology for deep space travel or off-world settlement simply cannot be overstated.

In the more immediate future, 3D printing can be used to rapidly develop and deploy unmanned spacecraft. Tiny satellites (referred to as CubeSats) could be printed, assembled, and deployed by astronauts already in orbit. Innovations such as these could allow science missions to be planned and executed in months instead of years, and at a vastly reduced cost.

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Truly Terrible Dimensioned Drawings

December 14, 2017 by Brian Benchoff 147 Comments

I’m in the planning stages of a side project for Hackaday right now. It’s nothing too impressive, but this is a project that will involve a lot of electromechanical parts. This project is going to need a lot of panel mount 1/8″ jacks and sockets, vertical mount DIN 5 connectors, pots, switches, and other carefully crafted bits of metal. Mouser and Digikey are great for nearly every other type of electrical component, but when it comes to these sorts of electromechanical components, your best move is usually to look at AliExpress or DealExtreme, finding something close to what you need, and buying a few hundred. Is this the best move for a manufacturable product? No, but we’re only building a few hundred of these things.

I have been browsing my usual Internet haunts in the search for the right bits of stamped brass and injection molded plastic for this project, and have come to a remarkable conclusion. Engineers, apparently, have no idea how to dimension drawings. Drafting has been a core competency for engineers from the dawn of time until AutoCAD was invented, and now we’re finally reaping the reward: It’s now rare to find a usable dimensioned drawing on the Internet.

This post is going to be half rant, half explanation of what is wrong with a few of the dimensioned drawings I’ve found recently. Consider this an example of what not to do. There is no reason for the state of engineering drawing to be this bad.

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Christal Gordon: Sensors, Fusion, And Neurobiology

December 12, 2017 by Al Williams 3 Comments

Some things don’t sound like they should go together, but they do. Peanut butter and chocolate. Twinkies and deep frying. Bacon and maple syrup. Sometimes mixing things up can produce great results. [Dr. Christal Gordon’s] expertise falls into that category. She’s an electrical engineer, but she also studies neuroscience. This can lead to some interesting intellectual Reese’s peanut butter cups.

At the 2017 Hackaday Superconference, [Christal] spoke about sensor fusion. If you’ve done systems that have multiple sensors, you’ve probably run into that before even if you didn’t call it that. However, [Christal] brings the perspective of how biological systems fuse sensor data contrasted to how electronic systems perform similar tasks. You can see a video replay of her talk in the video below.

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Living On The Moon: The Challenges

December 12, 2017 by Steven Dufresne 185 Comments

Invariably when we write about living on Mars, some ask why not go to the Moon instead? It’s much closer and has a generous selection of minerals. But its lack of an atmosphere adds to or exacerbates the problems we’d experience on Mars. Here, therefore, is a fun thought experiment about that age-old dream of living on the Moon.

Inhabiting Lava Tubes

Lava tube with collapsed pits near Gruithuisen crater

The Moon has even less radiation protection than Mars, having practically no atmosphere. The lack of atmosphere also means that more micrometeorites make it to ground level. One way to handle these issues is to bury structures under meters of lunar regolith — loose soil. Another is to build the structures in lava tubes.

A lava tube is a tunnel created by lava. As the lava flows, the outer crust cools, forming a tube for more lava to flow through. After the lava has been exhausted, a tunnel is left behind. Visual evidence on the Moon can be a long bulge, sometimes punctuated by holes where the roof has collapsed, as is shown here of a lava tube northwest from Gruithuisen crater. If the tube is far enough underground, there may be no visible bulge, just a large circular hole in the ground. Some tubes are known to be more than 300 meters (980 feet) in diameter.

Lava tubes as much as 40 meters (130 feet) underground can also provide thermal stability with a temperature of around -20°C (-4°F). Having this stable, relatively warm temperature makes building structures and equipment easier. A single lunar day is on average 29.5 Earth days long, meaning that we’ll get around 2 weeks with sunlight followed by 2 weeks without. During those times the average temperatures on the surface at the equator range from 106°C (224°F) to -183°C (-298°F), which makes it difficult to find materials to withstand that range for those lengths of time.

But living underground introduces problems too.

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Skin (Effect) In The Game

November 22, 2017 by Al Williams 70 Comments

We love to pretend like our components are perfect. Resistors don’t have capacitance or inductance. Wires conduct electricity perfectly. The reality, though, is far from this. It is easy to realize that wire will have some small resistance. For the kind of wire lengths you usually encounter, ignoring it is acceptable. If you start running lots of wire or you are carrying a lot of current, you might need to worry about it. Really long wires also take some time to get a signal from one end to the other, but you have to have a very long wire to really worry about that. However, all wires behave strangely as frequency goes up.

Of course there’s the issue of the wire becoming a significant part of the signal’s wavelength and there’s always parasitic capacitance and inductance. But the odd effect I’m thinking of is the so-called skin effect, first described by [Horace Lamb] in 1883. [Lamb] was working with spherical conductors, but [Oliver Heaviside] generalized it in 1885.

Put simply, when a wire is carrying AC, the current will tend to avoid traveling in the center of the wire. At low frequencies, the effect is minimal, but as the frequency rises, the area in the center that isn’t carrying current gets larger. At 60 Hz, for example, the skin depth for copper wire — the depth where the current falls below 1/e of the value near the surface — is about 0.33 inches. Wire you are likely to use at that frequency has a diameter less than that, so the effect is minimal.

However, consider a 20 kHz signal — a little high for audio unless you are a kid with good ears. The depth becomes about 0.018 inches. So wire bigger than 0.036 inches in diameter will start losing effective wire size. For a 12-gauge wire with a diameter of 0.093 inches, that means about 25% of the current-handling capacity is lost. When you get to RF and microwave frequencies, only the thinnest skin is carrying significant current. At 6 MHz, for example, copper wire has a skin depth of about 0.001 inches. At 1 GHz, you are down to about 0.000081 inches. You can see this (not to scale) in the accompanying image. At DC, all three zones of the wire carry current. At a higher frequency, only the outer two zones carry significant current. At higher frequencies, only the outer zone is really carrying electrons.