2024 Business Card Challenge: CardTunes Bluetooth Speaker

July 20, 2024 by Donald Papp 8 Comments

A business card form factor can be quite limiting, but that didn’t stop [Schwimmflugel] from creating CardTunes, an ESP32-based Bluetooth audio speaker that tried something innovative to deliver the output.

What’s very interesting about this design is the speaker itself. [Schwimmflugel] aimed to create a speaker out of two coils made from flexible circuit board material, driving them with opposite polarities to create a thin speaker without the need for a permanent magnet.

The concept is sound, but in practice, performance was poor. One could identify the song being played, but only if holding the speaker up to one’s ear. The output was improved considerably with the addition of a small permanent magnet behind the card, but of course this compromised the original vision.

Even though the concept of making a speaker from two flexible PCB panel coils had only mixed success, we love seeing this kind of effort and there’s a lot to learn from the results. Not to mention that it’s frankly fantastic to even have a Bluetooth speaker on a business card in the first place.

The 2024 Business Card Challenge is over, but judging by all the incredible entries we received, we’re thinking it probably won’t be too long before we come up with another sized-constrained challenge.

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Five Ways To Repair Broken PCB Traces

July 14, 2024 by Al Williams 23 Comments

When everything used wires, it was easy to splice them or replace them. Not so much with PC boards, but everyone has their favorite method for repairing a broken trace. [Mr. SolderFix] has his five favorite ways, as you can see in the video below.

Of course, before you can repair a trace, you probably have to expose it since most boards have solder mask now. Unless you plan to shut the trace at both ends, exposing the actual trace is probably the first step.

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Bringing The 555 Mini-Notebook To Video

July 10, 2024 by Alexander Rowsell 17 Comments

Like many of us [AnotherMaker] is a fan of the classic Forrest Mims electronics books, specifically, the Engineer’s Mini-Notebook series. They were great sources of inspiration, but at the time, he couldn’t afford to actually build most of the circuits described. Now as an adult, he decided to go through the 555 Timer IC Circuits Mini-Notebook, full of example circuits and explanations, all in Mims’ trademark handwritten style, and build all the circuits for real. And so, a series of YouTube videos are currently being released going over every circuit, how it works, and looking at waveforms on an oscilloscope!

So, PCBs were designed, each containing four of the circuits from the book. With the Mims circuit diagram on one side of the screen and the PCB on the other, [AnotherMaker] goes into a good amount of detail explaining how each circuit works, referring to the schematic and oscilloscope as needed. Each part in the series focuses on the next circuits in order, and eventually the whole series will cover every single circuit in the book.

It’s a great series of videos for anyone learning electronics, especially those who would like to learn about one of the most produced integrated circuits of all time! It’s also an excellent way to bring a fresh perspective to this classic book, while simultaneously bringing the content to a wider audience via online video.

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PCB Design Review: HAB Tracker With ATMega328P

July 10, 2024 by Arya Voronova 15 Comments

Welcome to the Design Review Central! [VE3SVF] sends us their board, and it’s a HAB (High Altitude Balloon) tracker board. It’s got the venerable ATMega28P on it, a LoRa modem and a GPS module, and it can be powered from a LiIon battery. Stick this board with its battery onto a high-altitude balloon, have it wake up and transmit your coordinates every once in a while, and eventually you’ll find it in a field – if you’re lucky. Oherwise, it will get stuck hanging on a tree branch, and you will have to use a quadcopter to try and get it down, and then, in all likelihood, a second quadcopter so that you can free the first one. Or go get a long ladder.

The ATMega328P is tried and true, and while it’s been rising in price, it’s still available – with even an updated version that sports a few more peripherals; most importantly, you’re sure to find a 328P in your drawer, if not multiple. Apart from that, the board uses two modules from a Chinese manufacturer, G-Nice, for both GPS and Lora. Both of these modules are cheap, making this tracker all that more accessible; I could easily see this project being sold as a “build your own beacon” kit!

Let’s make it maybe a little nicer, maybe a little cheaper, and maybe decrease the power consumption a tad along the way. We’ll use some of the old tricks, a few new ones, and talk about project-specific aspects that might be easy to miss.

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Dad? Where Did Printed Circuit Boards Come From?

July 5, 2024 by Al Williams 18 Comments

These days, it is hard to imagine electronics without printed circuit boards. They are literally in everything. While making PCBs at home used to be a chore, these days, you design on a computer, click a button, and they show up in the mail. But if you go back far enough, there were no PC boards. Where did they come from? That’s the question posed by [Steven Leibson] who did some investigating into the topic.

There were many false starts at building things like PCBs using wires glued to substrates or conductive inks. However, it wasn’t until World War II that mass production of PC boards became common. In particular, they were the perfect solution for proximity fuzes in artillery shells.

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The Best DIY PCB Method?

June 23, 2024 by Elliot Williams 23 Comments

Now before you start asking yourself “best for what purpose?”, just have a look at the quality of the DIY PCB in the image above. [ForOurGood] is getting higher resolution on the silkscreen than we’ve seen in production boards. Heck, he’s got silkscreen and soldermask at all on a DIY board, so it’s definitely better than what we’re producing at home.

The cost here is mostly time and complexity. This video demonstrating the method is almost three hours long, so you’re absolutely going to want to skip around, and we’ve got some relevant timestamps for you. The main tools required are a cheap 3018-style CNC mill with both a drill and a diode laser head, and a number of UV curing resins, a heat plate, and some etchant.

[ForOurGood] first cleans and covers the entire board with soldermask. A clever recurring theme here is the use of silkscreens and a squeegee to spread the layer uniformly. After that, a laser removes the mask and he etches the board. He then applies another layer of UV soldermask and a UV-curing silkscreen ink. This is baked, selectively exposed with the laser head again, and then he cleans the unexposed bits off.

In the last steps, the laser clears out the copper of the second soldermask layer, and the holes are drilled. An alignment jig makes sure that the drill holes go in exactly the right place when swapping between laser and drill toolheads – it’s been all laser up to now. He does a final swap back to the laser to etch additional informational layers on the back of the board, and creates a solder stencil to boot.

This is hands-down the most complete DIY PCB manufacturing process we’ve seen, and the results speak for themselves. We would cut about half of the corners here ourselves. Heck, if you do single-sided SMT boards, you could probably get away with just the first soldermask, laser clearing, and etching step, which would remove most of the heavy registration requirements and about 2/3 of the time. But if it really needs to look more professional than the professionals, this video demonstrates how you can get there in your own home, on a surprisingly reasonable budget.

This puts even our best toner transfer attempts to shame. We’re ordering UV cure soldermask right now.

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2024 Business Card Challenge: Integrated Game Card

June 21, 2024 by Dave Rowntree 10 Comments

[Dan Schnur] has a simple strategy to ensure their business card stays on the client’s desk and doesn’t just get lobbed in a drawer: make it into a simple gaming platform. This entry into the 2024 Business Card Challenge is based around the tinyjoypad project, integrating an SSD1306 OLED display, joypad, and push button.

Powered by the superstar ATTiny85, the electronics are really not all that much, just a sprinkling of passives to support the display and the six switch inputs from the joystick and push button. Or at least, that’s how much we can glean from the PCB images, as the PCB design files are not provided in the project GitHub.

Leaving the heavy lifting of the software to the tinyjoypad project, the designer can concentrate on the actual job at hand and the reason the business card exists to stay at the forefront of the client’s mind. In the meantime, the card can be a useful distraction for those idle moments. A few such distractions include a tiny version of Missile Command (as shown above), tiny tris, and a very cut-down Q-bert. Sadly, that last game isn’t quite the same without that distinctive sound.