Proper Routing Makes For Many Happy Return Paths

Here’s a question for you: when your PCB has a ground plane layer, where do return signals flow? It seems like a trick question, but as [Kristof Mulier] explains, there’s more to return path routing (alternate link in case you run into a paywall) than just doing a copper pour and calling it a day.

Like so many other things in life, the answer to the above question is “it depends,” and as [Kristof] ably demonstrates in this concise article, the return path for a signal largely depends on its frequency. He begins by explaining current loop areas and how they factor into the tendency for a circuit to both emit and be susceptible to electromagnetic noise. The bigger the loop area, the worse things can get from a noise perspective. At low frequencies, return signals will tend to take the shortest possible path, which can result in large current loop areas if you’re not careful. At higher frequencies, though, signals will tend to follow the path of minimal energy instead, which generally ends up being similar to the signal trace, even if it has a huge ground plane to flow through.

Since high-frequency signals naturally follow a path through the ground plane that minimizes the current loop, that means the problem takes care of itself, right? It would, except that we have a habit of putting all kinds of gaps in the way, from ground plane vias to isolation slots. [Kristof] argues that this can result in return paths that wiggle around these features, increasing the current loop area to the point where problems creep in. His solution? Route all your signal return paths. Even if you know that the return traces are going to get incorporated into a pour, the act of intentionally routing them will help minimize the current loop area. It’s brilliantly counterintuitive.

This is the first time we’ve seen the topic of high-frequency return paths tackled. This succinct demonstration shows exactly how return path obstructions can cause unexpected results.

Thanks to [Marius Heier] for the tip.

Share Your Projects: KiCad Automations And Pretty Renders

I have a pretty large GitHub repository, with all of my boards open-sourced there. Now, I’m finally facing the major problem it has – it can be uncomfortable for others to work with. I don’t store Gerber files in the repository because that will interfere with how Git functions – you’re supposed to only have source files in the repo. Yet, when someone needs Gerbers for my PCB, or a schematic PDF, or just to see how the board looks before they clone the entire repository, I often don’t have a good option for them.

In my experience as a hacker, being able to find others’ PCBs on GitHub is simply wonderful, but a PCB repository without a README feels barren, and a PCB README without pictures makes me sad. On the other hand, not having these files autogenerate is uncomfortable – updating a picture every time is a major drawback in particular.

Let’s take a look at some KiCad Git integrations, and see what they have to offer.

kicad_cli

We’ve mentioned kicad_cli back when KiCad 7 got released, and in the recently released KiCad 8, it’s only become more powerful. Before, it could do gerbers and schematic PDFs, but now, it can even do DRC checks – which is ideal if you want to add a hook for any pull requests you might encounter.

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Fabbing A Fab New Watch Face

[STR-Alorman] is into vintage watches, particularly Omega Seamaster quartz numbers from the 1980s. Among his favorites is the Seamaster Calypso III, a precious few of which were created in a lovely and rare black-on-black colorway. [STR-Alorman] found one on online, but it had a number of problems including a scratched-up face. Having done a respectable amount of PCB design and assembly, he decided to make a new face and have it fabbed.

The one angle where you can even tell this is a PCB.

After taking scale-referenced photos with a DSLR, [STR-Alorman] created vectors in Illustrator and then ported those to KiCad. He sent two versions to the board house — one with holes at index points, and one without — because he wasn’t sure which would be better for applying the luminization compound that makes them glow. Spoiler alert: it was the one with the cutouts.

Once this was done, [STR-Alorman] reassembled the movement, which doesn’t look easy at all, and involved getting the height of a bit of CA glue just right so as not to interfere with the movement of the date wheel. He replaced the bezel insert, re-luminized the hands, and now has a beautiful timepiece.

We believe only the nerdiest of nerds could tell this is a PCB, and they would need exactly the right light to make that determination. Here’s a watch that leaves no doubt about it.

The Pi Pico replacement board in question, assembled, held diagonally in some type of holder

ProPico For Your Pro Pico Needs

Ever feel like the Pi Pico board could be doing way more given its footprint? Does it bother you that the RP2040’s ADC quality is even further decreased because of the noisy onboard switching regulator? Miffed about decisions like the MicroUSB socket, the 2MB flash, or lack of the reset button? [Dmytro] brings us an open-source Pi Pico design, sporting the same RP2040 and a fully compatible footprint, but adding a number of improvements to its surroundings.

There’s a good few additions, all of them hacker-friendly – [Dmytro] adds comfortably-spaced reset and boot buttons, a USB-C socket, a dedicated low-noise voltage reference for the ADC, one more LED, and an I2C EEPROM footprint socket that is compatible with FRAM chips. Everything worth preserving is preserved – the pinout stays the same, including the SWD connector, which now sports an extra RESET pin. The bottom side USB testpoints remain, with only the four testpoints changed for more useful signals. Last but not least, the switching regulator is replaced by the venerable 1117 – you lose the ability to power your Pico from two AAs, and the capacitor series resistor requirement isn’t great, but you can easily put one of the drop-in 1117 replacement regulators on there.

What’s great is that the design is fully open-source, with KiCad files available. Want to design your own Pi Pico footprint board, improve upon this one even further, or maybe make a more tailored one? Treat yourself to the GitHub repository! There’s also a pinout diagram and a KiCanvas schematic for all your tinkering needs. We’ve covered drop-in replacements for classic drawer-inhabiting parts like the Pi Zero, for the 7805 (twice!), the 6502 CPU, and even for the DE9 serial port connector. No matter the purpose, they’re always a joy to see.

render of a sample board produced with help of this plugin. it's pretty, has nice lighting and all!

From KiCad To Blender For A Stunning Render

We love Blender. It brings you 3D modeling, but not in a CAD way — instead, people commonly use it to create animations, movies, games, and even things like VR models. In short, Blender is about all things art and visual expression. Now, what if you want a breathtaking render of your KiCad board? Look no further than the pcb2blender tool from [Bobbe 30350n].

This isn’t the first time we’ve seen KiCad meet Blender. However, compared to the KiCad to Blender paths that people used previously, pcb2blender makes the import process as straightforward and as quick as humanly possible. Install a plugin for both tools, and simply transfer a .pcb3d file out of the KiCad plugin into the Blender plugin. Want to make the surfaces of your design look like they’re meant to look in real life? Use the free2ki plugin to apply materials to your 3D models. In fact, you should check out [30350n]’s Blender plugin collection and overall portfolio, it’s impressive.

There’s no shortage of Blender hacks – just this year we’ve covered a hacker straight up simulating an entire camera inside Blender for the purpose of making renders, and someone else showing how to use Stable Diffusion to texture 3D scenes at lightning speed. We even recently published a comprehensive tutorial on how to animate your robot in Blender ourselves! Want to give it a shot? Check out this quick and simple Red Bull can model design tutorial.

Thanks to [Aki] for sharing this with us!

An Animated LED Fireplace Powered By The CH32V003

Once you’ve mastered the near-magical ability of turning your ideas into a piece of hardware you can hold in your hand, it’s only natural that you’ll want to spread the joy. The holidays are a perfect time to produce a custom piece of electronics for friends and family, but there’s a catch: going from making one or two of something to making dozens of them can introduce some interesting challenges. Not only will you want to cost optimize your design, but to save yourself some aggravation, you’ll likely want to simplify the assembly process.

The fifty electronic fireplaces designed by built by [Adam Anderson], [Daniel Quach], and [Johan Wheeler] are a perfect example of both concepts, and while we’re coming across it a bit late for this year’s gift exchange, we wouldn’t be surprised if these MIT-licensed beauties end up under a few more trees in 2024.

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Check Your Board: Call For Submissions

As both beginning hackers and Silicon Valley investors alike keep discovering, there are a lot of differences between hardware and software. One important difference is cost of iterating over a design. In software, you can comfortably rerun your build process and push updates out near instantly to tons of users. In hardware, all of that costs money, and I do mean, it costs way more money than you’d want to spend.

When I see people order boards that could never work because of some fundamental design assertions, with mistakes entirely preventable, it hurts. Not in an “embarrassment” way – it’s knowing that, if they asked someone to take a look at the design, they could’ve received crucial feedback, pulled the traces on the board differently or added some components, and avoided spending a significant chunk of money and time expecting and assembling a board that has a fundamental mishap.

Every thing like this might set a beginner back on their hacker journeys, or just have them spend some of their valuable time, and we can do a ton to prevent that by simply having someone experienced take a look.

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