AOI By DIY

February 11, 2021 by Jenny List 27 Comments

As anyone who has ever assembled a run of PCBs will tell you, quality inspection of solder joints can be a difficult process. Even under a microscope their appearances can be deceptive, and one silver blob can be perfect while its neighbour conceals a problem. The electronics industry have developed inspection tools to help, including optical inspection devices. It’s one of these that [Sina Roughani] has built, in the form of a hemispherical 3D printed dome with concentric rings of coloured LEDs mounted within it.

The principle behind this tool is as unexpected and simple as it is clever; by having different colours of light from different elevations of the dome it ensures that each different angle of the solder joint surface reflects a different colour. Thus a colour photograph shot from directly above the board allows visual inspection of the quality of the solder joints by the rainbow of colours that appears around their edges. This process can even be automated with OpenCV or similar, hence the process is referred to as Automated Optical Inspection, or AOI.

The technique is demonstrated with some pictures of a Raspberry Pi Pico, on which it shows really well the rainbow-edged solder joints and the red colour reflected from flat pads. What at first might seem like a novelty lighting effect becomes a very useful inspection tool.

PCB inspection is a subject we’ve covered before, though perhaps we don’t all have access to X-rays.

A Hair-Raising Twist On Infinity Mirrors

February 10, 2021 by Kristina Panos 6 Comments

Just when we thought we’d seen it all in the infinity mirror department, [FieldCrafting] blazed a tiny, shiny new trail with their electroplated infinity mirror hair pin. We’d sure like to stick this in our French twist. Fortunately, [FieldCrafting] provided step-by-step instructions for everything from the 3D printing to the copper electroplating to the mirror film and circuitry application.

And what tiny circuitry it is! This pin is powered by a coin cell and even has a micro slider switch to conserve it. The stick parts are a pair of knitting needles, which is a great idea — they’re pointy enough to get through hair, but not so pointy that they hurt.

[FieldCrafting] was planning to solder 1206 LEDs to copper tape and line the cavity with it, but somehow the CAD file ended up with 0603, so there wasn’t enough space for two tape traces. We think it’s probably for the better — [FieldCrafting]’s solution was to use two-conductor wire, strategically stripped, which seems a lot less fiddly than trying to keep two bare tape traces separated and passing pixies.

Don’t have enough hair for one of these? Surely you could use some handsome infinity coasters to round out that home bar setup.

Teardown: Bug Zapper Bulb

February 9, 2021 by Tom Nardi 17 Comments

Up here in the Northern Hemisphere, mosquitoes and other flying pests are the last thing on anyone’s mind right now. The only bug that’s hindering gatherings at the moment goes by the name of COVID-19, but even if we weren’t social distancing, insects simply aren’t a concern at this time of year. So it’s little surprise that these months are often the best time to find a great deal on gadgets designed to deter or outright obliterate airborne insects.

Case in point, I was able to pick up this “Bug Zapper LED Bulb” at the big-box hardware store for just a few bucks. This one is sold by PIC Corporation, though some press release surfing shows the company merely took over distribution of the device in 2017. Before then it was known as the Zapplight, and was the sort of thing you might see advertised on TV if you were still awake at 3 AM. It appears there are several exceptionally similar products on the market as well, which are likely to be the same internally.

In all fairness, it’s a pretty clever idea. Traditional zappers are fairly large, and need to be hoisted up somewhere next to an electrical outlet. But if you could shrink one down to the size of a light bulb, you could easily dot them around the porch using the existing sockets and wiring. Extra points if you can also figure out a way to make it work as a real bulb when the bugs aren’t out. Obviously the resulting chimera won’t excel at either task, but there’s certainly something to be said for the convenience of it.

Let’s take a look inside one of these electrifying illuminators and see how they’ve managed to squeeze two very different devices into one socket-friendly package.

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A Modern Homage To The TIL311 Display

February 8, 2021 by Lewin Day 39 Comments

Back in the 1970s, there were a huge variety of esoteric LED displays on the market. One of those was the DIP-packaged TIL311 from Texas Instruments, capable of displaying hexadecimal, from 0-9 and A-F. While these aren’t readily available anymore, the deep red plastic packages had some beauty to them, so [Alex] set about making a modern recreation.

The build consists of a small PCB fitted with 20 LEDs, and a STM8S microcontroller to run the show. This can be used to emulate the original decoder logic on the TIL311, or programmed with other firmware in order to test the display or enable other display functions. Where the project really shines however is in the visual presentation. [Alex] has been experimenting with potting the hardware in translucent red resin to properly emulate the look of the original parts, which goes a long way to getting that cool 70s aesthetic. Attention to detail is top notch, with [Alex] going so far as to carefully select pins that most closely match the square-cut design on the original TIL311 part.

It’s a fun build that could be useful for a project when you can’t get working new old stock. We’ve seen similar efforts for Nixie tubes in the past. Video after the break.

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Transmit Your Gaze To This Fiber Optic LED Lamp

February 3, 2021 by Kristina Panos 8 Comments

Call us easily amused, but we think it’s pretty amazing what can be done with a microcontroller, some RGB LEDs, and a little bit of plastic. Case in point is [andrei.erdei]’s beautiful and quite approachable fiber optic LED lamp. It’s a desktop-friendly version of a similar piece [andrei] made that is roughly nine times the size of this one and hangs on the wall. The build may be simple, but the product is intricately lovely.

We really like the visual density of this lamp — it’s just the right amount of tubes and strikes a balance between being too sparse and too chaotic. As you might expect, there’s an Arduino and some RGB LED strips involved. But the key to this build is in the 16 pieces of side-glow plastic fiber optic tubing. Side-glow is designed to let light escape along the length of the tube as opposed to end-glow, which is made to minimize light loss from one end to the other like a data pipe. This allows for all sorts of fun effects, and you can watch [andrei.erdei] go slowly and soothingly through the different colors and modes in the demo video after the break. Make sure you watch long enough to see the tubes move like the old Windows 3D pipes screensaver

Already have too many knickknacks and wall hangings? You’re missing out on prime real estate — the ceiling. Check out this fiber optic ceiling installation that reacts to music.

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Dazzling Desktop Dodecahedron

January 31, 2021 by Kristina Panos 6 Comments

Much like us, [AGBarber] digs all the infinity polyhedra already out there, but laments the fact that almost all of them are too large to be used as desktop ~~distractions~~ conversation pieces. That’s probably because it’s a lot easier to build ’em big, but that didn’t stop [AGBarber] from trying, succeeding spectacularly, and paving the way for anyone who wants to take on the challenge of building a dazzling desk toy of their own.

We all know that all those little strips of LEDs have to be chained together somehow. Wires would work fine in a larger version, but at roughly softball size, they become a tedious and fiddly nightmare. So what did [AGBarber] do instead? That’s right, they designed two different types of custom corner PCBs. The 3D printed brackets that hold the LEDs and the panels together are no cakewalk, either — [AGBarber] recommends using a resin printer if you have access to one, though it isn’t strictly required.

Everything about this project is open source, including a bonus printable jig for gluing the brackets together at just the right angles. All the steps are well-documented, from applying the mirror film to programming the Wemos D1 mini that controls the lights [AGBarber] programmed in a ton of animations, too, which you can watch after the break.

Want to build a small infinity thingy that isn’t quite so difficult? Crack open a cold one and check out these cool coasters.

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LED Hourglass Moves Like The Real Thing

January 27, 2021 by Kristina Panos 6 Comments

If you want to waste time in a meaningful way, get yourself an hourglass. It’s simultaneously mesmerizing and terrifying to sit there and watch the seconds slip through the threshold that separates possibility from missed opportunity.

[Ty and Gig]’s LED hourglass is equally beautiful to watch. It doesn’t actually tell time, but that’s perfectly fine by us. What it does do is animate the LEDs to approximate grains of sand in gravity, no matter how the hourglass is tilted.

In either vertical orientation, the sand falls as long as there is some in the top. When the hourglass is horizontal, the LEDs settle just like real sand does. [Ty and Gig] achieved this with a whole lot of code that breaks the animation frames into structure arrays.

By contrast, the hardware part of this build is fairly simple: all that’s needed to replicate this build is some RGB LEDs a beefy power supply to drive them, an accelerometer, and a microcontroller.

[Ty and Gig] were planning to use an ESP8266, but misplaced it and went with an Arduino Mega instead. (You know what they say — buy a replacement and the one you lost will turn up almost immediately.) The beautiful frame is made from leftover purpleheart, a hardwood that turns purple with exposure to air. Check out the build video after the break.

Too lazy to reset your hourglass every hour? Here’s one that flips itself.

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