Fiber Laser Gives DIY PCBs A Professional Finish

April 7, 2025 by Tom Nardi 12 Comments

While low-cost professional PCB fabrication has largely supplanted making circuit boards at home, there’s still something to be said for being able to go from design to prototype in an afternoon. Luckily we aren’t limited to the old toner transfer trick for DIY boards these days, as CNC routers and powerful lasers can be used to etch boards quickly and accurately.

But there’s still a problem — those methods leave you with a board that has exposed traces. That might work in a pinch for a one-off, but such boards are prone to shorts, and frankly just don’t look very good. Which is why [Mikey Sklar] has been experimenting with applying both a soldermask and silkscreen to his homemade boards.

The process he describes starts after the board has already been etched. First he rolls on the soldermask, and then sandwiches the board between layers of transparency film and clear acrylic before curing it under a UV light. After two coats of the soldermask, the board goes into a fiber laser and the silkscreen and mask layers are loaded into the software and the machine is set to a relatively low power (here, 40%). The trick is that the mask layer is set to run four times versus the single run of the silkscreen, which ensures that the copper is fully exposed.

Since the board doesn’t need to be moved between operations, you don’t have to worry about the registration being off. The end result really does look quite nice, with the silkscreen especially popping visually a lot more than we would have assumed.

We’ve previously covered how [Mikey] uses his CNC router and fiber laser to cut out and etch the boards, so this latest installment brings the whole thing full circle. The equipment you’ll need to follow along at home isn’t cheap, but we can’t argue with the final results.

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Multifunctional USB controlled PCB on blue background

How A Tiny Relay Became A USB Swiss Army Knife

April 5, 2025 by Heidi Ulrich 17 Comments

Meet the little board that could: [alcor6502]’s tiny USB relay controller, now evolved into a multifunction marvel. Originally built as a simple USB relay to probe the boundaries of JLCPCB’s production chops, it has become a compact utility belt for any hacker’s desk drawer. Not only has [alcor6502] actually built the thing, he even provided instructions. If you happened to be at Hackaday in Berlin, you now might even own one, as he handed out twenty of them during his visit. If not, read on and build it yourself.

This thing is not just a relay, and that is what makes it special. Depending on a few solder bridges and minimal components, it shape-shifts into six different tools: a fan controller (both 3- and 4-pin!), servo driver, UART interface, and of course, the classic relay. It even swaps out a crystal oscillator for USB self-sync using STM32F042‘s internal RC – no quartz, less cost, same precision. A dual-purpose BOOT0 button lets you flash firmware and toggle outputs, depending on timing. Clever reuse, just like our mothers taught us.

It’s the kind of design that makes you want to tinker again. Fewer parts. More function. And that little smile when it just works. If this kind of clever compactness excites you too, read [alcor6502]’s build log and instructions here.

Supercon 2024: A New World Of Full-Color PCBs

March 26, 2025 by Lewin Day 12 Comments

Printed circuit boards were once so simple. One or two layers of copper etched on a rectangular fiberglass substrate, with a few holes drilled in key locations so components could be soldered into place. They were functional objects, nothing more—built only for the sake of the circuit itself.

Fast forward to today, and so much has changed. Boards sprout so many layers, often more than 10, and all kinds of fancy geometric features for purposes both practical and pretty. But what catches they eye more than that, other than rich, saturated color? [Joseph Long] came to the 2024 Hackaday Supercon to educate us on the new world of full color PCBs.

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Glow In The Dark PCBs Are Pretty Cool

March 24, 2025 by Lewin Day 11 Comments

What if circuit boards could glow in the dark? It’s a fun question, and one [Botmatrix] sought to answer when approached by manufacturer PCBWay to run a project together. It turns out that it’s quite possible to make glowing PCBs, with attractive results. (Video after the break.)

Specifically, PCBWay has developed a workable glow-in-the-dark silkscreen material that can be applied to printed circuit boards. As a commercial board house, PCBWay hasn’t rushed to explain how precisely they pulled off this feat, but we don’t imagine that it involved anything more than adding some glow-in-the-dark powder to their usual silkscreen ink, but we can only speculate.

On [Botmatrix]’s end, his video steps through some neat testing of the performance of the boards. They’re tested using sensors to determine how well they glow over time.

It might seem like a visual gimmick, and to an extent, it’s just a bit of fun. But still, [Botmatrix] notes that it could have some practical applications too. For example, glow-in-the-dark silkscreen could be used to highlight specific test points on a board or similar, which could be instantly revealed with the use of a UV flashlight. It’s an edge case, but a compelling one. It’s also likely to be very fun for creating visually reactive conference badges or in other applications where the PCB plays a major cosmetic role.

[Botmatrix] says these are potentially the first commercially-available glow-in-the-dark printed PCBs. We love glow in the dark stuff; we’ve even explored how to make your own glowing material before, too. .

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Aluminum Business Cards Make Viable PCB Stencils

March 21, 2025 by Lewin Day 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.

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A Decade Resistance Box From PCBs

March 13, 2025 by Jenny List 18 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.

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

March 10, 2025 by Heidi Ulrich 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.