Let Your Finger Do The Soldering With Solder Sustainer V2

April 11, 2024 by Dan Maloney 20 Comments

Soldering is easy, as long as you have one hand to hold the iron, one to hold the solder, and another to hold the workpiece. For those of us not so equipped, there’s the new and improved Solder Sustainer v2, which aims to free up one of however many hands you happen to have.

Eagle-eyed readers will probably recall an earlier version of Solder Sustainer, which made an appearance in last year’s Hackaday Prize in the “Gearing Up” round. At the time we wrote that it looked a bit like “the love child of a MIG welder and a tattoo machine.” This time around, [RoboticWorx] has rethought that concept and mounted the solder feeder on the back of a fingerless glove. The solder guide is a tube that clips to the user’s forefinger, which makes much finer control of where the solder meets the iron possible than with the previous version. The soldering iron itself is also no longer built into the tool, giving better control of the tip and letting you use your favorite iron, which itself is no small benefit.

Hats off to [RoboticWorx] for going back to the drawing board on this one. It isn’t easy to throw out most of your design and start over, but sometimes it just makes sense.

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Adjustable Lights Help Peer Inside Chips With IR

April 9, 2024 by Dan Maloney 3 Comments

If you’re used to working through a microscope, you’ve probably noticed that the angle of the light greatly affects how your workpiece looks. Most of us prefer the relatively flat lighting provided by a ring light, but variable angle side lighting can be useful too, especially when you’re peering inside ICs to make sure the silicon is what it’s supposed to be.

That’s what [Bunnie] is working on these days with his Project IRIS, short for “Infrared in situ,” a non-destructive method for looking inside chip packages. The technique relies on the fact that silicon is transparent to certain wavelengths of light, and that some modern IC packages expose the underside of the silicon die directly to the outside world. Initial tests indicated that the angle of the incident IR light was important to visualizing features on the metal interconnects layered onto the silicon, so [Bunnie] designed a two-axis light source for his microscope. The rig uses curved metal tracks to guide a pair of IR light sources through an arc centered on the focal point of the microscope stage. The angle of each light source relative to the stage can be controlled independently, while the whole thing can swivel around the optical axis of the microscope to control the radial angle of the lighting.

The mechanism [Bunnie] designed to accomplish all this is pretty complex. Zenith angle is controlled by a lead screw driving a connecting rod to the lights on their guide tracks, while the azimuth of the lights is controlled by a separate motor and pulley driving a custom-built coaxial bearing. The whole optical assembly is mounted on a Jubilee motion platform for XYZ control. The brief videos below show the lights being put through their paces, along with how changing the angle of the light affects the view inside a chip.

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Squishy Miter Saw Shroud Spares You The Sneezy Bits

April 7, 2024 by Sonya Vasquez 8 Comments

Let’s be honest. When it comes to operating miter saws, these tools kick dust out the back like a spray paint can. Most of us have accepted this quirk as-is, but not [Inspire Woodcraft] who’s on a mission to achieve near perfect dust collection. And he nearly has it. With a budget dust collection setup, he’s able to eliminate over 90% of the dust from his cuts, and others who’ve adopted his setup can vouch for his results.

The solution comes in two pieces. First, he focuses on creating a new dust shroud or “boot” for collecting dust through the vacuum hookup on the back of the saw. What’s key here is that this dust boot is made from squishy silicone, enabling it to flare outwards and spread out as the saw travels downward into the material. It’s clear that [Inspire Woodcraft] has gone through dozens of material and shape iterations, but the result is sturdy enough to stay open with the vacuum running through the back hose attachment.

With the dust nearly perfectly funneled from the back, the second tweak focuses on rerouting stray dust away from the table and directly into this boot. [Inspire Woodcraft] later noticed that dust collection from the bottom of his miter saw simply didn’t exist, so dust would accumulate at his feet.

His solution? To create a second shroud that fits under the throat plate that takes sawdust once destined for the ground and ejects it backwards and straight into the dust collection boot.

Altogether, this setup solves a long-existing problem with a handful of commodity parts and a few 3D prints. [Inspire Woodcraft] has also chronicled his journey in such detail where you too could recreate his solution from the video. But if you’re feeling lazy, and you’re lucky enough to own the same Dewalt DW716 or DWS716 model miter saws, you can simply snag a kit from his website.

If all this talk of miter saws has your reaching for a screwdriver to see what modified mayhem you can unleash with yours, look no further than this LED hack that adds a shadow line to your cuts.

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Comparing Desoldering Tools

April 7, 2024 by Al Williams 27 Comments

[Lee] has a Hakko FR301 desoldering gun and a Duratool knockoff. He freely admits that the Hakko is probably better, but he wonders if it’s good enough to justify being four times as expensive. He shows both of them off in a recent video that you can see below.

Often, desoldering doesn’t get as much attention as soldering, but for repairs or if you make mistakes — and who doesn’t — it is an essential skill. Many of the differences will be either good or bad, depending on your personal preference. For example, the Hakko is an all-in-one unit, so it doesn’t have a bulky box to sit on your bench. However, that also means the Hakko is larger and heavier. It also lacks controls and indicators the other unit has on the base station box.

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The line injector shown characterising the PSRR of an AMS1117 regulator, with a bunch of stuff connected to it through SMA jacks

A Simple Line Injector Shows You The Wonderful World Of PSRR

April 5, 2024 by Arya Voronova 8 Comments

[limpkin] writes us to show a line injector they’ve designed. The principle is simple — if you want to measure how much PSU noise any of your electronic devices let through, known as PSRR (Power Supply Rejection Ratio), you can induce PSU noise with this board, and then measure noise on your device’s output. The board is likewise simple. A few connectors, resistors, and caps, and a single N-FET!

You do need a VNA, but once you have that, you get a chance to peek into an entire world of insights. Does that 1117 LDO actually filter out noise better than a buck regulator? Is it enough to use a Pi filter for that STM32’s ADC rail, and do the actual parts you’re using actually help with that task? How much noise does your device actually let through in the real world, after being assembled with the specific components you’ve picked? [limpkin] shows us a whole bunch of examples – putting regulators, filters and amplifiers to the test, and showing us how there’s more than meets the eye.

Everything is open source, with full files available on the blog. And, if you want it pre-assembled, tested and equipped with the CNC-milled case, you can get it on Tindie or Lektronz! Of course, even without a tool like this, you can still get good filter designs done with help of computer-aided modelling.

We thank [alfonso] for sharing this with us!

Vibratory Rock Tumbler Bounces On Printed Spring

April 4, 2024 by Tom Nardi 26 Comments

If you’re reading Hackaday, there’s a good chance you had a rock tumbler in your younger days. Hell, we’d put odds on a few of you having one rumbling away in the background as you read this. They’re relatively simple contraptions, and a common enough DIY project. But even still, this largely 3D printed rock tumbler from [Fraens] is unique enough to stand out.

To make a basic rock tumbler, all you really need to do is rotate a cylindrical chamber and let physics do its thing. Such contraptions are known as, unsurprisingly, rotary rock tumblers. But what [Fraens] has put together here is a vibratory tumbler, which…well, it vibrates. If this was Rockaday we might go farther down this particular rabbit hole and explain the pros and cons of each machine, but the short version is that vibratory tumblers are more mechanically complex and are generally better suited to fine finish work than rotary tumblers which take a brute force approach that tends to round off the rocks.

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Showing the ESP-Prog-Adapter board plugged into the ESP-Prog adapter, wired to a SOIC clip, that then attaches to a PCB under test

ESP-Prog-Adapter Makes Your ESP32 Tinkering Seamless

April 3, 2024 by Arya Voronova 8 Comments

Did you ever struggle with an ESP32 board of yours, wishing you had exposed that UART, or seriously lacking the JTAG port access? If so, you should seriously check out [0xjmux]’s ESP-PROG-Adapter project, because [0xjmux] has put a lot of love and care into making your ESP32 hardware interfacing a breeze. This project shows you how to add JTAG and UART headers with extra low board footprint impact, gives you a KiCad library to do so super quickly, and shares a simple and helpful adapter PCB you can directly use with the exceptionally cheap Espressif’s ESP-Prog dongle you should have bought months ago.

The hardware is perfect for ZIF no-soldering interfacing – first of all, both UART and JTAG can be connected through a SOICBite connection, a solderless connector idea that lets you use SPI flashing clips on specially designed pads at the edge of your board. For the fancy toolkit hackers among us, there’s also a Tag Connect symbol suggested and a connector available, but it carries JTAG that you will already get with the SOICBite, so it’s maybe not worth spending extra money on.

Everything is fully open-source, as one could hope! If you’re doing ESP32 hacking, you simply have to order this board and a SOIC clip to go with it, given just how much trouble [0xjmux]’s board will save you when programming or debugging your ESP32 devices. Now, you don’t strictly need the ESP-Prog dongle – you could remix this into an adapter for the Pi Pico board instead. Oh, and if designing boards with ARM CPUs are your thing, you might benefit from being reminded about the Debug Edge standard!