Printing Printed Circuit Boards

November 12, 2013 by Brian Benchoff 65 Comments

circuit

We really respect the old timers out there and their amazing ways of crafting PCBs; they used black tape on clear acetate sheets to create single layers of PCBs with a photoetching process. Now creating a PCB is a simple matter of opening up a CAD package, but like the old timers we’re still dealing with nasty chemicals or long shipping times from China.

The EX¹, a new robot on Kickstarter – hopes to change that. They’ve created a PCB fabrication process that’s as simple as printing something with an inkjet printer. Just put in a piece of substrate – anything from Kapton to acrylic to fabric – and in a few minutes you have a single-sided PCB in your hands.

The printer dispenses two chemicals, silver nitrate and ascorbic acid, that react and produce traces and pads for the circuit. Right now, the EX¹ is limited to single-side boards, but experiments on creating multi layer boards are ongoing.

In any event, we’re really impressed with how simple the EX¹ setup actually is. Inkjet is a mature, well understood technology with more than enough resolution for simple homebrew circuits, and the AgNO3 + Vitamin C formula could easily be adapted to an inkjet printer modification.

Build Your Own Desoldering Station On The Cheap

November 11, 2013 by Todd Harrison 34 Comments

[Sable Wolf] tipped us off to his DYI desoldering station for under $70. We know we have seen this conversion before, but it hasn’t been featured on Hack a Day. [Sable Wolf’s] hack is unique and has added features that make building, cleaning and the overall longevity sounder. However, some kind of sound deadening housing would have to be built around the pump as it seemed uncomfortably loud in the video.

Some Chinese made desoldering stations are getting quite cheap so maybe it’s not worth the effort unless you can salvage more components for the build. Thanks to [Sable Wolf’s] detailed blog you can browse through his BOM and scrounge up the majority of these items from your salvage bins. A cheap but reliable desoldering station would be an extremely handy tool to have on your bench.

This is much safer than desoldering with a candle or using fire as featured in the past, and is kind of a flip around on the SMD hot air pencil hack.

Follow long after the break to watch the video of the desoldering station in action.

Continue reading “Build Your Own Desoldering Station On The Cheap” →

Make Any Shape Board In Eagle

November 10, 2013 by Brian Benchoff 21 Comments

circuit2

[Bryan] has been working on a very nice analog LED clock circuit, but when it came time to lay out the parts in Eagle, he was somewhat miffed by the inability to create designs in his Eagle boards. Eagle is a fine tool for laying out circuits, but when it comes to making strangely shaped PCBs, Eagle just isn’t the right tool.

The solution to this problem was to create the board outline in OpenSCAD. The desired shape of [Bryan]’s clock was easily designed, but importing the shape into an Eagle layer was another matter entirely.

OpenSCAD, though, can output 2D shapes to the DXF format. Getting the DXF board into Eagle required [Bryan] to write a script that outputs Eagle WIRE commands. Pasting these commands into the command line gave [Bryan] a perfectly shaped PCB.

Since DXF is supported by every drawing package on the planet, [Bryan]’s 20 line script could also be used for much more intricate designs. If you have an incredibly complex Illustrator drawing that deserves to be a PCB, it doesn’t get much easier than tossing it through a script.

Guitar Amp Turned Tool Cabinet

November 6, 2013 by James Hobson 4 Comments

amp cabinet

While HANDMADE.hackaday was a rather ephemeral experiment, we still come across some mighty fine examples of handmade projects that we think deserve to grace the pages of Hack a Day. As is the case with this beautifully repurposed guitar amp turned tool cabinet.

After gutting the original amp, [Max] set to bending some 22ga steel plate into drawers. He enjoys using that particular gauge because its fairly easy to cut and bend, while still being rigid enough for most applications. Once content with the bending jobs, he attached ball bearing roller slides to the sides and installed the drawers. Making use of the original amp face for the top drawer he cleaned up all the edges and gave it some new paint — it’s a beautifully crafted example of what you can do with a bit of sweat and elbow grease!

And for the audiophiles, don’t worry — the amp wasn’t functional before it was cannibalized for its casing.

[Via Reddit]

Manufacturer-Crippled Flir E4 Thermal Camera Hacked To Perform As High-End Model

November 4, 2013 by Brian Benchoff 136 Comments

Last month, [Mike] took a look at the Flir E4 thermal imaging camera. It’s a great tool for those occasions when you need the vision of a Predator, but what he found inside was substantially cooler: it seems the engineers behind the Flir E4 made their lives easier by making the circuits inside the $1000 E4 the same as the $6000 Flir E8.

This only means one thing, and [Mike] has delivered. He’s upgraded the firmware in the Flir E4 to the E8, giving it a vastly increased resolution – 80×40 for the E4 to 320×240 for the E8.

The hack itself is as easy as putting the serial number of the E4 in a config file, zipping a few files up, and installing it with the Flir tools. An amazingly simple mod (with an awesome teardown video) that turns a $1000 thermal imaging camera into the high-end $6000 model.

Continue reading “Manufacturer-Crippled Flir E4 Thermal Camera Hacked To Perform As High-End Model” →

Adorable Homebrew Waveform Generator

November 2, 2013 by Brian Benchoff 25 Comments

waveform

For want of new test equipment, or simply a project, [Enzo] decided he would take a shot at creating his own waveform generator*. Not only is it a great project, it’s also a decent piece of test equipment, with proper signal conditioning, a nice front panel, and a built-in wall transformer.

The guts of [Enzo]’s waveform generator is an AD9833 programmable waveform generator, a neat little chip that can output square and triangle waves fro 0.1 Hz to 3.2 MHz and sine waves from 0.1 Hz to 1.6 MHz. [Enzo] is controlling this chip with a PIC16 microcontroller, with a whole bunch of analog circuitry between the digital domain and the BNC connector on the front panel.

The waveform generator is controlled by a suite of dials and switches on the front panel, giving [Enzo] complete control over his new tool.

* Here’s a Google translation, but good luck with that. Just… get Chrome or something.

Perfect PCBs With An Inkjet Printer

November 2, 2013 by Brian Benchoff 69 Comments

Instead of mucking about fabbing PCBs with the toner transfer method, or making masks for photosensitive boards, the holy grail of at-home circuit board manufacturing is a direct inkjet-to-etch method. [Don] isn’t quite there yet, but his method of producing circuit boards at home is one of the easiest we’ve ever seen.

[Don]’s boards begin by taking the output from Eagle and printing them with an Epson Artisan 50 inkjet printer. By sticking a piece of cardstock in the printer before the copper board, he’s able to precisely align the traces and pads onto the copper board.

When the board comes out of the printer, it’s only covered in ink. While some specialty inks are enough of an etch resist, [Don] comes up with a clever way to make sure acid doesn’t eat away copper in the needed places – he simply dusts on toner from a copier or laser printer, blows off the excess, and bakes the entire board in a toaster oven.

The result, seen above, are perfect traces on a circuit board without the need for ironing sheets of photo paper onto copper boards.

As far as the, “why didn’t someone think of this sooner” ideas go, this one is at the top. [Don] says the method should work on sheets of aluminum for printing solder paste masks. Impressive work, and now the only thing left to do is getting two-layer boards down pat. For more direct to copper printing check out the hacks we’ve covered in years past.

Continue reading “Perfect PCBs With An Inkjet Printer” →