Tool Hacks

2965 Articles

Make PCBs With DLP, OMG!

January 7, 2016 by 48 Comments

There’s so many ways to skin the home-fabrication-of-PCBs cat! Here’s yet another. [Nuri Erginer] had a DLP projector on hand, and with the addition of some reducing optics, managed to turn it into a one-shot PCB exposer.

If you’ve ever used photo-resist PCB material before, you know the drill: print out your circuit onto transparency film, layer the transparency with the sensitized PCB, expose with a UV light for a while, dissolve away the unexposed resist, and then etch. Here, [Nuri] combines the first three steps in one by exposing the board directly from a DLP projector.

The catch is that the projector’s resolution limits the size of the board that you can make. To fab a board that’s 10cm x 10cm, at XGA resolution (1024×768), you’ll end up with a feature size of around 0.004″ in the good direction and 0.005″ in the other.

For DIP parts, that’s marginal, but for fine-pitch or small SMT parts, that won’t do. On the other hand, for a smaller board, optimally one in the same 4:3 ratio, it could work. And because it exposes in one shot, you can’t beat the speed. Cool hack, [Nuri]!

When you need more precision, strapping a UV laser to an accurate 2D robot is a good way to go, but it’s gonna take a while longer.

Using Acetone To Create Print Transfers

January 7, 2016 by 40 Comments

Looking for an easy way to print transfer a logo or image? Don’t have time to get transfer paper? Did you know you can use… regular paper? Turns out there’s a pretty awesome method that just uses Acetone to transfer the ink!

Using a laser printer, print off your desired logo or image. Don’t forget to mirror it! Place the paper onto the material you would like to transfer the graphic to, face down. It works best on wood and cloth, but can also be done on metal, glass and even plastic!  Continue reading “Using Acetone To Create Print Transfers” →

Helping Gorilla Hands

January 6, 2016 by 19 Comments

Helping hands are a common soldering aid. These inexpensive devices usually have a substantial base, a pair of alligator clips to hold a workpiece, and sometimes a magnifying glass. [Yonatan24] (who happens to be 13 years old) built his own set using a siren horn as a base. Lately, however, he decided to enhance it quite a bit to use Gorillapod arms and incorporate a solder cleaning and a variety of other features. Of course, there is a magnifier along with a solder waste collection bin.

The build is well-detailed, although since [Yonatan24] salvaged some of the parts, you might have to make adjustments to match the parts you use. The Gorillapod arms are from a cheap tripod, but a lot of the material was left over or stripped from junk (like the lead weight).

We’ve seen workbench PCB holders before (including a 3D printed one), of course, but you have to admire the look of this one, as well as the overboard set of features.

DIY Hakko Soldering Station

January 5, 2016 by 8 Comments

[Julez] wanted another soldering station, so he decided to build one himself using a Hakko 907 soldering iron (or a clone). Of course, he could have bought a station, but anyone who reads Hackaday doesn’t require an explanation for why you would build something you could buy.

The station has two switchable outputs so you can use two different irons (perhaps with different tips) although you can only use one at a time. [Julez] bought a case with a transparent top from eBay and also got a digital temperature controller from eBay, which is the heart of the project. As for the actual iron, you can find clone versions of the 907 handpiece for well under $10.

Because the station uses a module, the actual wiring isn’t terribly difficult. There’s a pot to control the temperature and the controller directly connects to the iron’s heating element and temperature probe. There’s also a standby switch that reduces the temperature using a fixed resistor in series with the control pot.

Continue reading “DIY Hakko Soldering Station” →

BGA Hand Soldering Video

January 3, 2016 by 31 Comments

By 2016, most people have got the hang of doing SMD soldering in the garage–at least for standard packaging. Ball Grid Array or BGA, however, remains one of the more difficult packages to work with [Colin O’Flynn] has an excellent video (almost 30-minutes, including some parts that are sped up) that shows exactly how he does a board with BGA.

Continue reading “BGA Hand Soldering Video” →

DIY Mini Butane Torch Would Make MacGyver Proud

January 2, 2016 by 22 Comments

Need to MacGyver yourself out of a situation with a mini torch? Well, you might want to watch this video of how to make a mini butane torch out of some random household components.

Built by [Roman UrsuHack], almost all the parts in this assembly are being used completely not as manufacturer intended. Which is why we love it. And why it’s a bit dangerous too.

Using an inkjet printer cartridge refill syringe, a bicycle pump needle, some tubing, a few compression valves (they look almost like medical equipment, for blood donation), a water bottle, a can of butane, lots of hot glue, and a few bicycle pump fittings, [Roman] has created a rather ingenious little butane torch.

Continue reading “DIY Mini Butane Torch Would Make MacGyver Proud” →

Desoldering Doesn’t Necessarily Suck

December 28, 2015 by 37 Comments

What’s your favorite way to fix soldering mistakes or get usable components off that board you found in a Dumpster? I’ve always been partial to desoldering braid, though I’ve started to come around on the vacuum pump depending on the situation. [Proto G] sent in an Instructable that outlines nine different ways to desolder components that take varying amounts of time and skill.

He starts with one that is often overlooked if you don’t have a solder pot. [Proto G] recommends this method only when you don’t want to keep the board. Cover the solder joints of the components you want to keep with flux and hold it over the solder pot while pulling out the components with pliers. The flux isn’t critical, but it makes removal faster and easier.

For boards in need of repair, [Proto G] uses a manual pump or copper desoldering braid that comes coated with flux. If you can afford one, a desoldering machine seems like the way to go—it combines the heat of a soldering iron with the vacuum of a manual pump. Desoldering tweezers and hot air rework stations look like great ways to remove surface mount components.

If you enjoyed this, check out [Bil Herd’s] guide on component desoldering. There are also few ways that [Proto G] doesn’t mention, like holding the board over an alcohol flame. Let us know your favorite desoldering method in the comments.

Continue reading “Desoldering Doesn’t Necessarily Suck” →