PCB Hacks

85 Articles

Aluminum Business Cards Make Viable PCB Stencils

March 21, 2025 by 25 Comments

[Mikey Sklar] had a problem—namely, running low on the brass material typically used for making PCB stencils. Thankfully, a replacement material was not hard to find. It turns out you can use aluminum business card blanks to make viable PCB stencils.

Why business card blanks? They’re cheap, for a start—maybe 15 cents each in quantity. They’re also the right thickness, at just 0.8 mm 0.18 mm, and they’re flat, unlike rolled materials that can tend to flip up when you’re trying to spread paste. They’re only good for small PCBs, of course, but for many applications, they’ll do just fine.

To cut these, you’ll probably want a laser cutter. [Mikey] was duly equipped in that regard already, which helped. Using a 20 watt fiber laser at a power of 80%, he was able to get nice accurate cuts for the stencils. Thanks to the small size of the PCBs in question, the stencils for three PCBs could be crammed on to a single card.

If you’re not happy with your existing PCB stencil material, you might like to try these aluminium blanks on for size. We’ve covered other stenciling topics before, too.

Continue reading “Aluminum Business Cards Make Viable PCB Stencils” →

A Decade Resistance Box From PCBs

March 13, 2025 by 19 Comments

One of those useful things to have around on your bench is a decade resistance box, essentially a dial-a-resistance instrument. They used to be quite expensive in line with the cost of close-tolerance resistors, but the prices have come down and it’s within reach to build your own. Electronic design consultancy Dekimo have a nice design for one made from a series of PCBs which they normally give out at trade fairs, but now they’ve released the files for download.

It’s released as Gerbers and BOM with a pick-and-place file only, and there’s no licence so it’s free-as-in-beer [Editor’s note: the license has been updated to CC-BY-SA], but that should be enough if you fancy a go. Our Gerber viewer is playing up so we’re not entirely sure how reliable using PCBs as wafer switches will be long-term, but since the pictures are all ENIG boards we’d guess the gold plating will be much better than the HASL on all those cheap multimeters.

We like this as a conference giveaway, being used to badges it’s refreshing to see a passive take on a PCB artwork. Meanwhile this isn’t the first resistance box we’ve seen with unconventional switches.

Soviet ZX Spectrum clone on a table

ZX Spectrum, Soviet Style: A 44-IC Clone You Can Build

March 10, 2025 by 12 Comments

If you’ve ever fancied building a ZX Spectrum clone without hunting down ancient ULAs or soldering your way through 60+ chips, [Alex J. Lowry] has just dropped an exciting build. He has recreated the Leningrad-1, a Soviet-built Spectrum clone from 1988, with a refreshingly low component count: 44 off-the-shelf ICs, as he wrote us. That’s less than many modern clones like the Superfo Harlequin, yet without resorting to programmable logic. All schematics, Gerbers, and KiCad files are open-source, listed at the bottom of [Alex]’ build log.

The original Leningrad-1 was designed by Sergey Zonov during the late Soviet era, when cloning Western tech was less about piracy and more about survival. Zonov’s design nailed a sweet spot between affordability and usability, with enough compatibility to run 90-95% of Spectrum software. [Alex]’ replica preserves that spirit, with a few 21st-century tweaks for builders: silkscreened component values, clever PCB stacking with nylon standoffs, and a DIY-friendly mechanical keyboard hack using transparent keycaps.

While Revision 0 still has some quirks – no SCART color output yet, occasional flickering borders with AY sound – [Alex] is planning for further improvements. Inspired to build your own? Read [Alex]’ full project log here.

Custom Touchpad PCBs Without The Pain

March 6, 2025 by 11 Comments

Many of us use touch pads daily on our laptops, but rarely do we give much thought about what they really do. In fact they are a PCB matrix of conductive pads, with a controller chip addressing it and sensing the area of contact. Such a complex and repetitive pattern can be annoying to create by hand in an EDA package, so [Timonsku] has written a script to take away the work.

It starts with an OpenSCAD script (originally written by Texas Instruments, and released as open source) that creates a diamond grid, which can be edited to the required dimensions and resolution. This is then exported as a DXF file, and the magic begins in a Python script. After adjustment of variables to suit, it finishes with an Eagle-compatible board file which should be importable into other EDA packages.

We’ve never made a touchpad ourselves, but having dome other such repetitive PCB tasks we feel the pain of anyone who has. Looking at this project we’re struck by the thought that its approach could be adapted for other uses, so it’s one to file away for later.

This isn’t the first home-made touchpad project we’ve brought you.

PCB Dielectric Constant Measurements, Three Ways

February 25, 2025 by 4 Comments

FR4 is FR4, right? For a lot of PCB designs, the answer is yes — the particular characteristics of the substrate material don’t impact your design in any major way. But things get a little weird up in the microwave range, and having one of these easy methods to measure the dielectric properties of your PCB substrate can be pretty handy.

The RF reverse-engineering methods [Gregory F. Gusberti] are deceptively simple, even if they require some fancy test equipment. But if you’re designing circuits with features like microstrip filters where the permittivity of the substrate would matter, chances are pretty good you already have access to such gear. The first method uses a ring resonator, which is just a PCB with a circular microstrip of known circumference. Microstrip feedlines approach but don’t quite attach to the ring, leaving a tiny coupling gap. SMA connectors on the feedline connect the resonator to a microwave vector network analyzer in S21 mode. The resonant frequencies show up as peaks on the VNA, and can be used to calculate the effective permittivity of the substrate.

Method two is similar in that it measures in the frequency domain, but uses a pair of microstrip stubs of different lengths. The delta between the lengths is used to cancel out the effect of the SMA connectors, and the phase delay difference is used to calculate the effective permittivity. The last method is a time domain measurement using a single microstrip with a couple of wider areas. A fast pulse sent into this circuit will partially reflect off these impedance discontinuities; the time delay between the reflections is directly related to the propagation speed of the wave in the substrate, which allows you to calculate its effective permittivity.

One key takeaway for us is the concept of effective permittivity, which considers the whole environment of the stripline, including the air above the traces. We’d imagine that if there had been any resist or silkscreen near the traces it would change the permittivity, too, making measurements like these all the more important.

Continue reading “PCB Dielectric Constant Measurements, Three Ways” →

Demonstration of the multichannel design feature, being able to put identical blocks into your design, only route one of them, and have all the other blocks' routing be duplicated

KiCad 9 Moves Up In The Pro League

February 22, 2025 by 28 Comments

Do you do PCB design for a living? Has KiCad been just a tiny bit insufficient for your lightning-fast board routing demands? We’ve just been graced with the KiCad 9 release (blog post, there’s a FOSDEM talk too), and it brings features of the rank you expect from a professional-level monthly-subscription PCB design suite.

Of course, KiCad 9 has delivered a ton of polish and features for all sorts of PCB design, so everyone will have some fun new additions to work with – but if you live and breathe PCB track routing, this release is especially for you.

Continue reading “KiCad 9 Moves Up In The Pro League” →

PCB Design Review: M.2 SSD Splitter

February 12, 2025 by 20 Comments

Today’s PCB design review is a board is from [Wificable]. iI’s a novel dual-SSD laptop adapter board! See, CPUs and chipsets often let you split wide PCIe links into multiple smaller width links. This board relies on a specific laptop with a specific CPU series, and a BIOS mod, to put two M.2 NVMe SSDs into a single SSD slot of a specific series’ laptop.

This board has two crucial factors – mechanical compatibility, and electrical function. Looking into mechanics, it’s a 0.8 mm thick PCB that plugs into a M.2 socket, and it has sockets for two SSDs on it – plenty of bending going on. For electronics, it has a PCIe REFCLK clock buffer, that [Wificable] found on Mouser – a must have for PCIe bifurcation, and a must-work for this board’s core! Apart from that, this is a 4-layer board, it basically has to be for diffpairs to work first-try.

Of course, the clock buffer chip is the main active component and the focus of the board, most likely mistakes will happen there – let’s look at the chip first.

Continue reading “PCB Design Review: M.2 SSD Splitter” →